Differential Case: Disassembly

REMOVE SPEEDOMETER DRIVE GEAR
1. Remove the speedometer drive gear from the front differential case.
  
  Fig 1: Identifying Speedometer Drive Gear And Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place matchmarks on the front differential ring gear and the front differential case.
2. Remove the 8 bolts.
3. Using a plastic hammer, remove the front differential ring gear from the front differential case.
  
  Fig 3: Locating Front Differential Ring Gear And Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
1. Fix the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.
  Standard backlash:
  
  0.05 to 0.20 mm (0.0020 to 0.0079 in.)
  
  If the backlash is outside the specifications, replace the side gear thrust washers.
  
  Fig 4: Measuring Front Differential Side Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a chisel and a hammer, loosen the staked part of the front differential case.
  
  Fig 5: Identifying Front Differential Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (ø3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
  
  Fig 6: Removing Front Differential Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 FRONT DIFFERENTIAL PINION SHAFT
1. Remove the No. 1 front differential pinion shaft from the front differential case.
  
  Fig 7: Identifying No. 1 Front Differential Pinion Shaft And Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL SIDE GEAR
1. Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 No. 1 front differential side gear thrust washers and 2 front differential side gears from the front differential case.
  HINT:
  
  Revolving the front differential pinion, remove the 2 pinions and 2 side gears.
  
  Fig 8: Identifying Front Differential Side Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002