Differential Case: Disassembly

REMOVE SPEEDOMETER DRIVE GEAR
1. Remove the speedometer drive gear from the front differential case.
  
  Fig 1: Identifying Speedometer Drive Gear
  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.
  
  Fig 2: Identifying Matchmarks On Front Differential Ring Gear And Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer, remove the front differential ring gear from the front differential case.
  
  Fig 3: Locating Front Differential Ring Gear Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
1. Secure 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 (0.00197 to 0.00787 in.)
  
  If the backlash is out of specification, adjust it using new side gear thrust washers (See REASSEMBLY ).
  
  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: Loosening Staked Part Of Front Differential Case
  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 From Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT
1. Remove the front No. 1 differential pinion shaft from the front differential case.
  
  Fig 7: Identifying Front No. 1 Differential Pinion Shaft
  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:
  
  While rotating 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