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Disassembly [12/2013 - 08/2014]: 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 DIFFERENTIAL RING GEAR 
    1. Put matchmarks on the front differential ring gear and differential case.
      GTY434553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    2. Remove the 12 bolts from the front differential ring gear.
      GTY444804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, remove the front differential ring gear from the differential case.
      GTY289488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE Front DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case front tapered roller bearing from the differential case.
      GTY423587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09950-00020 
      • SST: 09950-00030 
      • 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 
  3. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case rear tapered roller bearing from the differential case.
      GTY447043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09950-00020 
      • SST: 09950-00030 
      • 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.
      GTY453185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
  4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Using a 3 mm pin punch and a hammer, remove the front differential pinion shaft straight pin from the differential case.
      GTY128999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Before removing the front differential pinion shaft straight pin, release the staked part of the differential case with a pin punch.

  5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT 
    1. Remove the front No. 1 differential pinion shaft from the differential case.
      GTY442124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE DIFFERENTIAL SIDE GEAR 
    1. Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 differential side gears and 2 front No. 1 differential side gear thrust washers from the differential case.
      GTY455966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Differential Pinion
      *2 Front Differential Pinion Thrust Washer
      *3 Differential Side Gear
      *4 Front No. 1 Differential Side Gear Thrust Washer
  7. REMOVE FRONT DRIVE SHAFT OIL SEAL RH 
    1. Outside:
      1. Using SST, remove the front drive shaft oil seal RH from the transaxle housing.
        GTY443309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09308-00010 
    2. Inside:
      1. Using SST, remove the front drive shaft oil seal RH from the differential case.
        • SST: 09308-00010 
        GTY441070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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 
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