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Disassembly [08/2014 - 11/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Highlander, 2015 Toyota Highlander, and 2014 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE FRONT DRIVE SHAFT OIL SEAL RH 
    1. for Outside:
      1. Using SST, remove the front drive shaft oil seal RH from the transaxle housing.
        GTY427459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09308-00010 
    2. for Inside:
      GTY473134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST, remove the front drive shaft oil seal RH from the front differential case.
        • SST: 09308-00010 
  2. REMOVE FRONT DRIVE SHAFT OIL SEAL LH 
    1. Using SST, remove the front drive shaft oil seal LH from the transaxle case sub-assembly.
      GTY423694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
  3. INSPECT FRONT DIFFERENTIAL CASE 

    See step  1 , or see step  1

  4. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT 

    See step  2 , or see step  2

  5. REMOVE FRONT DIFFERENTIAL RING GEAR 
    1. Put matchmarks on the front differential ring gear and front differential case.
      GTY472300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    2. Remove the 12 bolts from the front differential ring gear.
      GTY474611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, tap on the front differential ring gear to remove it from the front differential case.
      GTY474455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Secure the front differential case in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Using a 5 mm pin punch and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
      GTY473913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT 
    1. Remove the front No. 1 differential pinion shaft from the front differential case.
      GTY473912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT FRONT DIFFERENTIAL PINION BACKLASH 

    See step  3 , or see step  3

  9. REMOVE FRONT DIFFERENTIAL SIDE GEAR 
    1. Install SST as shown in the illustration and tighten it.
      GTY477393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn *b Hold
      • SST: 09528-52010 
        1. 09528-05010
        2. 09953-05010
      NOTE:

      Do not overtighten SST, as doing so will damage the front differential side gears, conical springs, front No. 1 differential side gear thrust washers and front differential case.

      HINT: 

      • Tighten SST until there is clearance between the front differential pinions and front differential side gears.
      • When removing the front differential pinions, do not overtighten SST, as it is necessary to rotate the front differential side gears.
    2. Install SST as shown in the illustration, rotate the front differential side gear, and then remove the 2 front differential pinions and 2 front differential pinion thrust washers from the front differential case.
      GTY472166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      • SST: 09528-52010 
        1. 09528-05030
      NOTE:

      Do not drop the front differential pinion and front differential pinion thrust washer.

    3. Remove SST from the front differential case, and then remove the 2 front differential side gears, 2 front No. 1 differential side gear thrust washers and 2 conical springs from the front differential case.
      GTY475919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Differential Side Gear
      *2 Conical Spring
      *3 Front No. 1 Differential Side Gear Thrust Washer
      NOTE:

      Do not drop the front differential side gear, front No. 1 differential side gear thrust washer or conical spring.

  10. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case front tapered roller bearing (inner race) from the front differential case.
      GTY476487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-40011 
        1. 09957-04010
      • SST: 09950-60010 
        1. 09951-00480
    2. Using SST, remove the front differential case front tapered roller bearing (outer race) and shim from the transaxle housing.
      GTY433744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
  11. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.
      GTY475814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-40011 
        1. 09957-04010
      • SST: 09950-60010 
        1. 09951-00480
    2. Using SST, remove the front differential case rear tapered roller bearing (outer race) from the transaxle case sub-assembly.
      GTY476334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
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