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Disassembly [12/2015 - 08/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST, remove the front transaxle case oil seal from the transaxle housing.
      GTY473853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
  2. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL 
    1. Using SST, remove the front differential case oil seal from the front differential case.
      GTY472857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
  3. REMOVE TRANSAXLE CASE OIL SEAL 
    1. Using SST, remove the transaxle case oil seal from the transaxle case.
      GTY708060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
  4. INSPECT FRONT DIFFERENTIAL CASE 

    See step  1

  5. INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT 

    See step  2

  6. REMOVE FRONT DIFFERENTIAL RING GEAR 
    1. Put matchmarks on the front differential ring gear and front differential case.
      GTY736930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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
  7. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN 
    1. Secure the front differential case in a vise between aluminum plates.
      GTY473913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  8. 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
  9. INSPECT FRONT DIFFERENTIAL PINION BACKLASH 

    See step  3

  10. REMOVE FRONT DIFFERENTIAL SIDE GEAR 
    1. Install SST as shown in the illustration and tighten it.
      GTY721877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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.
      GTY472215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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.
      GTY725266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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.

  11. 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.
      GTY481571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-40011 
        1. 09957-04010
      • SST: 09950-60010 
        1. 09951-00480
      NOTE:

      Apply a small amount of grease to the threads and tip of SST (center bolt) before use.

    2. Using SST, remove the front differential case front tapered roller bearing (outer race) and shim from the transaxle housing.
      GTY473228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
  12. 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.
      GTY723030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-40011 
        1. 09957-04010
      • SST: 09950-60010 
        1. 09951-00480
      NOTE:

      Apply a small amount of grease to the threads and tip of SST (center bolt) before use.

    2. Using SST, remove the front differential case rear tapered roller bearing (outer race) from the transaxle case.
      GTY721675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
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