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 10 bolts.
  
  Fig 2: Identifying Front Differential 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, remove the front differential case tapered roller bearing front inner race from the differential case.
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00340)
  
  Fig 4: Identifying Front Differential Case Tapered Roller Bearing Front Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case tapered roller bearing front outer race and differential case washer.
  SST 09387-00041 (09387-01030, 09387-01040, 09387-02010, 09387-02020)
  
  Fig 5: Identifying Front Differential Case Tapered Roller Bearing Front Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case tapered roller bearing rear inner race from the differential case.
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00340)
  
  Fig 6: Identifying Front Differential Case Tapered Roller Bearing Rear Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case tapered roller bearing rear outer race from the differential case washer.
  SST 09387-00041 (09387-01030, 09387-01040, 09387-02010, 09387-02020)
  
  Fig 7: Identifying Front Differential Case Tapered Roller Bearing Rear Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a punch and hammer, loosen the staked part of the differential case.
  
  Fig 8: Identifying Staked Part Of Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (5 mm), tap out the pin from the ring gear side.
  
  Fig 9: Identifying Tapping Out 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 10: Identifying Front Differential Pinion Shaft
  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 11: Identifying Front Differential Side Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
1. Place the transaxle case in a vise.
2. Using SST, remove the oil seal.
  SST 09308-00010
  
  Fig 12: Identifying Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSAXLE HOUSING OIL SEAL

Fig 13: Identifying Transaxle Housing Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Place the transaxle housing in a vise.
2. Using SST, remove the oil seal.
  SST 09308-00010