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 FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the front differential case front tapered roller bearing from the differential case.
  SST 09950-40011 (09951 -04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00390)
  
  Fig 1: Identifying Front Differential Case Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case RH tapered roller bearing outer race from the transaxle housing.
  SST 09387-00041 (09387-02020, 09387-02010)
  
  Fig 2: Identifying Front Differential Case RH Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPEEDOMETER DRIVE GEAR
1. Remove the speedometer drive gear from the differential case.
  
  Fig 3: Identifying Speedometer Drive Gear
  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 from the differential case.
  SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00430)
  
  Fig 4: Identifying Front Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case tapered roller bearing outer race from the transaxle case.
  SST 09612-65014 (09612-01010)
  
  Fig 5: Identifying Front Differential Case Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place matchmarks on the front differential ring gear and differential case.
  
  Fig 6: Identifying Matchmarks On Front Differential Ring Gear And Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, release the lock plate.
  SST 09930-00010
  
  Fig 7: Identifying Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 8 bolts and the lock plate.
  
  Fig 8: Identifying Bolts And Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plastic hammer, remove the front differential ring gear from the differential case.
  
  Fig 9: Identifying Front Differential Ring Gear From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a punch and a hammer, release the differential case.
  
  Fig 10: Identifying Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and a hammer, remove the straight pin.
  
  Fig 11: Identifying Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT
1. Remove the pinion shaft from the front differential case.
  
  Fig 12: Identifying Pinion Shaft From Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL SIDE GEAR
1. Remove the 2 pinions, 2 thrust washers, 2 side gears and 2 thrust washers No. 1 from the front differential case.
  
  Fig 13: Identifying Pinions, Thrust Washers, Side Gears And Thrust Washers No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002