Differential Case: Disassembly

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 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00390)
  
  Fig 1: Removing 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 from the transaxle housing.
  SST 09387-00041 (09387-02010, 09387-02020)
  
  Fig 2: Removing Front Differential Case Front Tapered Roller Bearing Outer Race From Transaxle Housing
  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 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00430)
  
  Fig 3: Removing Front Differential Case Rear Tapered Roller Bearing From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the outer race and shim.
  SST 09612-65014 (09612-01010)
  
  Fig 4: Removing Outer Race And Shim
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPEEDOMETER DRIVE GEAR
1. Remove the speedometer drive gear from the differential case.
  
  Fig 5: Removing Speedometer Drive Gear From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place matchmarks on the front differential ring gear and differential case.
  
  Fig 6: Identifying Matchmarks On Front Differential Ring Gear And Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, unstake the lock plate.
  SST 09930-00010
  
  Fig 7: Removing Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 8 bolts and lock plate.
  
  Fig 8: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a plastic-faced hammer, tap out the front differential ring gear from the differential case.
  
  Fig 9: Taping Out Front Differential Ring Gear From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch and hammer, unstake the differential case.
  
  Fig 10: Removing Front Differential Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, tap out the straight pin.
  
  Fig 11: Taping Out Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL NO. 1 PINION SHAFT
1. Remove the pinion shaft from the front differential case.
  
  Fig 12: Removing Pinion Shaft From Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL SIDE GEAR
1. Remove the 2 pinions, 2 thrust washers, 2 side gears and 2 thrust washers from the front differential case.
  
  Fig 13: Removing Front Differential Side Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL DRIVE PINION PLUG
1. Using a brass bar and plastic-faced hammer, tap out the differential drive pinion plug.
  
  Fig 14: Taping Out Differential Drive Pinion Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COUNTER DRIVEN GEAR
1. Using SST and a press, press out the counter driven gear from the differential drive pinion.
  SST 09950-60010 (09951-00350), 09950-70010 (09951-07150)
  
  Fig 15: Pressing Out Counter Driven Gear From Differential Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002