Disassembly

Fig. 18 Exploded view of differential assembly. Pickup, 4Runner & Van:

1. Place carrier assembly on a suitable workbench.

2. Loosen staked portion of companion flange locknut, then retain flange using tool No. 09330-00021 and remove nut.

3. Remove companion flange using tool No. 09557-22022.

4. Remove oil seal, using tool No. 09557-22022, then the oil slinger.

5. Remove front bearing front drive pinion, using tool No. 09556-30010, then the bearing spacer.

6. Mark relative position between bearing cap and differential carrier, then remove 2 adjusting locknuts, bearing caps, adjusting nuts, bearing outer races and differential case from carrier. Tag components as to original location to facilitate installation.

7. Remove drive pinion from differential carrier.

8. If necessary to replace drive pinion rear bearing, proceed as follows:
a. Remove rear bearing from drive pinion, using tool No. 09950-00020.
b. Install washer on drive pinion with chamfer end facing pinion gear.
c. Press washer and new rear bearing onto drive pinion, using tool No. 09506-30011.

9. If necessary to replace drive pinion front and rear bearing outer race, proceed as follows:
a. Drive out outer bearing race using a hammer and suitable drift.
b. Press in new outer race using suitable tool.

10. Remove side bearing from differential case using tool No. 09950-20016.

11. Remove ring gear attaching bolts and lock plates, then mark relative position between ring gear and differential case. Separate ring gear from case by tapping on ring gear, using a suitable mallet.

12. Drive out straight pin, then remove pinion shaft, two pinion gears, side gears and thrust washers from differential case.