Center Differential: Disassembly

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

CHECK HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE
1. Using a feeler gauge, measure the high speed output gear thrust clearance.
  Standard clearance: 0.10 to 0.25 mm (0.0039 to 0.0098 in.)
  
  Maximum clearance: 0.25 mm (0.0098 in.)
  
  Fig 1: Measuring High Speed Output Gear Thrust Clearance Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the clearance is greater than the maximum, replace the high speed output gear, needle roller bearing, high speed output gear bush low gear, clutch hub or front differential case.
2. Using a dial indicator, measure the high speed output gear radial clearance.
  Standard clearance: 0.035 to 0.091 mm (0.00138 to 0.00358 in.)
  
  Maximum clearance: 0.091 mm (0.00358 in.)
  
  If the clearance is greater than the maximum, replace the high speed output gear, needle roller bearing, high speed output gear bush low gear, clutch hub or front differential case.
  
  Fig 2: Measuring High Speed Output Gear Radial Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE GEAR PIECE
1. Using a snap ring expander, remove the snap ring.
2. Using SST and a press, remove the front drive gear piece.
  SST 09950-00020, 09950-60010 (09951-00320)
  
  NOTE: Be careful not to drop the center differential assembly.
  
  Fig 3: Removing Front Drive Gear Piece Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TAPER ROLLER BEARING
1. Using SST and a press, press out the taper roller bearing.
  SST 09950-00020
  
  NOTE: Set the claw of SST to the bearing inner race securely.
  
  Fig 4: Pressing Out Taper Roller Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HIGH SPEED OUTPUT GEAR
REMOVE HIGH AND LOW CLUTCH SLEEVE

Fig 6: Removing High & Low Clutch Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HIGH SPEED OUTPUT GEAR BUSH AND CLUTCH HUB
1. Using SST, remove the high speed output gear bush and clutch hub.
  SST 09950-00020, 09950-00030, 09950-60010 (09951-00320)
2. Using a magnetic finger, remove the straight pin from the front differential case.
  
  Fig 7: Removing High Speed Output Gear Bush & Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR TAPER ROLLER BEARING
1. Using SST and a press, press out the taper roller bearing.
  SST 09950-00020, 09950-60010 (09951-00320)
  
  NOTE: Set the claw of SST to the bearing inner race securely.
  
  Fig 8: Pressing Out Rear Taper Roller Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CASE
1. Remove the 12 bolts and differential case.
  
  Fig 9: Removing Rear Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE THRUST WASHER AND REAR SIDE GEAR

Fig 10: Removing Thrust Washer & Rear Side Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PINION SHAFT, PINION GEAR AND THRUST WASHER
1. Remove the straight pin from the pinion shaft.
  
  Fig 11: Removing Straight Pin From Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the pinion shaft, 2 pinion gears and 2 thrust washers.
  
  Fig 12: Removing Pinion Shaft, 2 Pinion Gears & 2 Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the front side gear and thrust washer.
  
  Fig 13: Removing Front Side Gear & Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOW GEAR
1. Using a plastic-faced hammer, tap out the low gear.
  NOTE: Be careful not to damage the low gear.
  
  Fig 14: Tapping Out Low Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002