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Disassembly [09/2022 - ]: Procedure

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  1. REMOVE FRONT DIFFERENTIAL RING GEAR 
    1. Mount the front differential ring gear in a vise between aluminum plates.
      NOTE:
      • Be careful not to damage the front differential ring gear.
      • Do not overtighten the vise.
    2. Put matchmarks on the front differential ring gear and front No. 1 differential case sub-assembly.
      GTY1024501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    3. Remove the 16 bolts.
      GTY1022506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a plastic-faced hammer, remove the front No. 1 differential case sub-assembly from the front differential ring gear.
  2. INSPECT FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY (w/o LSD) 

    See step  1

  3. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (w/o LSD) 
    1. Using a 5 mm pin punch and hammer, remove the front differential pinion shaft straight pin from the front No. 1 differential case sub-assembly.
      GTY1024456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT (w/o LSD) 
    1. Remove the front No. 1 differential pinion shaft from the front No. 1 differential case sub-assembly.
      GTY1024473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT FRONT DIFFERENTIAL PINION BACKLASH (w/o LSD) 

    See step  3

  6. REMOVE FRONT DIFFERENTIAL SIDE GEAR (w/o LSD) 
    1. Set SST as shown in the illustration and tighten it.
      GTY1024637Courtesy 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 gear, conical spring, front No. 1 differential side gear thrust washer and front No. 1 differential case sub-assembly.

      HINT: 

      • Tighten SST until there is a 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 No. 1 differential case sub-assembly.
      GTY1024600Courtesy 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 No. 1 differential case sub-assembly, 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 No. 1 differential case sub-assembly.
      GTY1024493Courtesy 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 and conical spring.

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