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Differential Case: Disassembly

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  1. REMOVE SPEEDOMETER DRIVE (MTM) GEAR 
    1. Remove the speedometer drive (MTM) gear from the front differential case.
    Fig 1: Identifying Speedometer Drive (MTM) Gear
    G04831932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE FRONT DIFFERENTIAL RING GEAR 
    1. Put matchmarks on the front differential ring gear and front differential case.
      Fig 2: Identifying Matchmarks On Front Differential Ring Gear And Front Differential Case
      G05194533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts.
    3. Using a hammer, remove the front differential ring gear.
  3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH  (see )INSPECTION 
    Fig 3: Locating Front Differential Ring Gear Bolts
    G05194534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a chisel and a hammer, loosen the staked part of the front differential case.
      Fig 4: Loosening Staked Part Of Front Differential Case
      G04831936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch (ø 3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
    Fig 5: Removing Front Differential Pinion Shaft Straight Pin From Front Differential Case
    G05194536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT DIFFERENTIAL PINION SHAFT NO. 1 
    1. Remove the front differential pinion shaft No. 1 from the front differential case.
    Fig 6: Identifying Front Differential Pinion Shaft No.1
    G05194537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FRONT DIFFERENTIAL SIDE GEAR 
    1. Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front differential side gear thrust washers and 2 front differential side gears from the front differential case.

      HINT:

      Turning the front differential pinion, remove the 2 pinions and 2 side gears.

  7. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER  (see )INSPECTION 
  8. INSPECT FRONT DIFFERENTIAL PINION SHAFT NO. 1  (see )INSPECTION 
Fig 7: Identifying Front Differential Side Gear
G05194538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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