Differential Case: Disassembly

WARNING: This page is about a different car, the 2008 Lexus RX 350. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place matchmarks on the ring gear and differential case.
  
  Fig 1: Aligning Matchmarks On Ring Gear And Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 16 bolts.
  
  Fig 2: Identifying Front Differential Ring Gear Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer, tap the ring gear to remove it from the case.
  
  Fig 3: Tapping Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL SIDE GEAR
1. Remove the differential LH case from the differential case assembly.
  
  Fig 4: Identifying Differential LH Case From Differential Case Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 2 differential case from the differential case LH.
  
  Fig 5: Identifying No. 2 Differential Case From Differential Case LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the front differential side gear, front differential side gear thrust washer, conical spring, and center differential side gear thrust washer No. 2 from the differential case LH.
  
  Fig 6: Identifying Front Differential Side Gear, Front Differential Side Gear Thrust Washer And Conical Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a snap ring expander, remove the pinion shaft spacer snap ring.
  
  Fig 7: Removing Pinion Shaft Spacer Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a pin punch and hammer, remove the 3 straight pins.
  
  Fig 8: Tapping Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the center differential pinion shaft and 2 differential pinion shafts.
  
  Fig 9: Identifying Center Differential Pinion Shaft And Differential Pinion Shafts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the 4 front differential pinions, 4 front differential pinion thrust washers, front differential pinion shaft holder, front differential planetary ring, and No. 1 differential side gear thrust washer.
  
  Fig 10: Identifying Front Differential Pinions And Front Differential Pinion Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case rear tapered roller bearing from the differential case.
  SST 09950-00020, 09950-00030, 09950-60010 (09951-00480)
  
  Fig 11: Removing Front Differential Case Rear Tapered Roller Bearing From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case rear tapered roller bearing outer race and differential case washer.
  SST 09308-00010
  NOTE:
  - When replacing the bearing, be sure to replace both outer and inner races.
  - When replacing the bearing, be sure to replace both left and right bearings as a set.
    
    Fig 12: Removing Front Differential Case Rear Tapered Roller Bearing Outer Race And Differential Case Washer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL PINION
1. Using a "TORX" socket (T50), remove the 15 bolts.
  
  Fig 13: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place matchmarks on the differential intermediate case and differential case.
3. Remove the differential intermediate case from the differential case RH.
  
  Fig 14: Identifying Differential Intermediate Case And Differential Case RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the center differential side gear, conical spring washer, and center differential side gear thrust washer No. 1 RH from the differential case RH.
  
  Fig 15: Identifying Center Differential Side Gear, Conical Spring Washer, And Center Differential Side Gear Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the differential spider, 5 center differential pinions, and 5 center differential pinion thrust washers from the differential intermediate case.
  
  Fig 16: Identifying Differential Spider And Center Differential Pinions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the front differential case front tapered roller bearing from the differential case.
  SST 09950-00020,09950-00030
  
  SST 09950-60010 (09951-00600)
  
  Fig 17: Removing Front Differential Case Front Tapered Roller Bearing From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case front tapered roller bearing outer race and differential case washer.
  SST 09308-00010
  
  Fig 18: Removing Front Differential Case Rear Tapered Roller Bearing Outer Race And Differential Case Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSAXLE HOUSING OIL SEAL
1. Using SST, remove the oil seal.
  SST 09950-70010 (09951-07100)
  
  SST 09649-17010
  
  Fig 19: Removing Transaxle Housing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
1. Using SST, remove the oil seal.
  SST 09950-70010 (09951 -07100), 09608-10010
  
  Fig 20: Removing Differential Side Bearing Retainer Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002