Differential Case: Disassembly

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE SPEEDOMETER DRIVE GEAR
1. Remove the speedometer drive gear from the front differential case.
  
  Fig 1: Identifying Speedometer Drive Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place matchmarks on the front differential ring gear and the front differential case.
2. Remove the 8 bolts.
  
  Fig 2: Placing Matchmarks On Front Differential Ring Gear & Front Different Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer, remove the front differential ring gear from the front differential case.
  
  Fig 3: Identifying Plastic Hammer & Front Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
1. Fix the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.
  Standard backlash:
  
  0.05 to 0.20 mm (0.0020 to 0.0079 in.)
  
  If the backlash is outside the specifications, replace the side gear thrust washers.
  
  Fig 4: Measuring Front Differential Side Gear Backlash Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a chisel and a hammer, loosen the staked part of the front differential case.
  
  Fig 5: Identifying Chisel, Hammer & Staked Part Of Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (ø3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
  
  Fig 6: Identifying Pin Punch, Hammer & Front Differential Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL PINION SHAFT NO.1
1. Remove front differential pinion shaft No. 1 from the front differential case.
  
  Fig 7: Identifying Front Differential Pinion Shaft No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 No. 1 and 2 front differential side gears from the front differential case.
  HINT:
  
  Revolving the front differential pinion, remove the 2 pinions and 2 side gears.
  
  Fig 8: Identifying Front Differential Side Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002