Differential Case: Disassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place the matchmarks on the ring gear and differential case.
  
  Fig 1: Identifying Matchmarks On Ring Gear And Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 14 bolts.
  
  Fig 2: Identifying Differential Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic-faced hammer, tap on the ring gear to remove it from the case.
  
  Fig 3: Identifying Tapping On Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, tap out the front differential case front tapered roller bearing from the differential case.
  SST 09950-00020, 09950-00030, 09950-60010 (09951-00500)
  
  Fig 4: Identifying Tapping Out Front Differential Case Front Tapered Roller Bearing From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case front tapered roller bearing outer race.
  SST 09308-00010
  
  Fig 5: Identifying Front Differential Case Front Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case rear tapered roller bearing from the differential case.
  SST 09950-00020, 09950-00030, 09950-60010 (09951-00500)
  
  Fig 6: Identifying Front Differential Case Rear Tapered Roller Bearing From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, tap out the front differential case front tapered roller bearing outer race.
  SST 09308-00010
  
  Fig 7: Identifying Tapping Out Front Differential Case Front Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch and hammer, tap in the straight pin.
  NOTE: Before removing the straight pin, unstake it with a pin punch.
  
  Fig 8: Identifying Tapping In Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 FRONT DIFFERENTIAL PINION SHAFT
1. Remove the front differential pinion shaft from the differential case.
  
  Fig 9: Identifying Front Differential Pinion Shaft From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL SIDE GEAR
1. Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears and 2 side gear thrust washers from the differential case.
  
  Fig 10: Identifying Front Differential Side Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSAXLE HOUSING OIL SEAL
1. Using SST and hammer, tap out the oil seal.
  SST 09950-70010 (09951-07100), 09215-00013 (09215-00471)
  
  Fig 11: Identifying Tapping Out Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
1. Using SST and hammer, tap out the oil seal.
  SST 09950-70010 (09951-07100), 09608-10010
  
  Fig 12: Identifying Tapping Differential Side Bearing Retainer Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002