Center Differential: Disassembly

WARNING: This page is about a different car, the 2002 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

Inspect high speed output gear radial and thrust clearance .
1. Using a feeler gauge, measure the high speed output gear thrust clearance.
  
  Fig 1: Measuring High Speed Output Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard clearance :
  1. 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
  Maximum clearance :
  1. 0.25 mm (0.0098 in.)
2. Using a dial indicator, measure the high speed output gear radial clearance.
  
  Fig 2: Measuring High Speed Output Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard clearance :
  1. 0.035 - 0.091 mm (0.00138 - 0.00358 in.)
  Maximum clearance :
  1. 0.091 mm (0.00358 in.)
Remove front drive gear piece .
1. Using a snap ring expander, remove the snap ring.
2. Using SST and a press, remove the front drive gear piece.
  
  Fig 3: Removing Front Drive Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-00020, 09950-60010 (09951-00320)
  
  NOTE: Be careful not to drop the center differential assembly.
Remove front taper roller bearing .
1. Using SST and a press, remove the front taper roller bearing.
  
  Fig 4: Removing Front Taper Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-00020
  
  NOTE: Set the claw of SST to the bearing inner race securely.
Remove high speed output gear .

Fig 5: Remove High Speed Output Gear & Needle Roller Bearings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove 2 needle roller bearings .
Remove high and low clutch sleeve .

Fig 6: Removing High & Low Clutch Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove high speed output gear bushing and clutch hub .
1. Using SST, remove the high speed output gear bushing and clutch hub.
  
  Fig 7: Removing High Speed Output Gear Bushing & Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-00020, 09950-00030, 09950-60010 (09951-00320)
2. Using a magnetic finger, remove the straight pin from the differential front case.
Remove rear taper roller bearing .
1. Using SST and a press, remove the rear taper roller bearing.
  
  Fig 8: Removing Rear Taper Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-00020, 09950-60010 (09951-00320)
  
  NOTE: Set the claw of SST to the bearing inner race securely.
Remove differential rear case .
1. Remove the 12 bolts and differential rear case.
  
  Fig 9: Locating Bolts For Removal Of Differential Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove thrust washer and rear side gear .

Fig 10: Removing Thrust Washer & Rear Side Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove pinion shaft, 2 pinion gears and 2 thrust washers .
1. Remove the straight pin from the pinion shaft.
  
  Fig 11: Removing Straight Pin From Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the pinion shaft, 2 pinion gears and thrust washers.
  
  Fig 12: Removing Pinion Shaft, Pinion Gears & Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the front side gear and thrust washer.
  
  Fig 13: Removing Front Side Gear & Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove low gear .
1. Using a plastic hammer, tap and remove the low gear.
  
  Fig 14: Removing Low Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE: Be careful not to damage the low gear.