Disassembly

Rear Differential Carrier / 2JZ-GTE M/T:

Rear Differential Carrier / Except 2JZ-GTE M/T:

DISASSEMBLY





NOTE: When fastening the differential carrier to an overhaul stand, etc., fasten it at the four places on the ring gear side shown in the illustration.

1. Remove side gear shaft, as follows:





a. Manual Transmission (M/T):
Equally tighten both bolts at the same time and pull out the side gear shaft.

NOTICE: Pull out the side gear shaft until a nut can fit behind the shaft. Pulling the shaft out too far will damage the dust cover.

Fig. 23 Removing Side Gear Shaft:

b. Using Special Service Tool (SST) 09520 - 24010 or equivalent, two bolts and nuts, remove the side gear shaft.
c. Using a screwdriver, remove the snap ring from the side gear shaft.





2. Remove side gear shaft oil seals. Using SST 09308 - 00010 or equivalent, remove the oil seal.
3. Remove differential carrier retainer (and adjusting plate washer), as follows:
a. Remove the eight bolts.





b. Manual Transmission (M/T):
Using SST 09550 - 10012 (09558 - 10010), 09950 - 40010 (09951 - 04010, 09952 - 04020, 09953 - 04020, 09954 - 04010, 09955 - 04070, 09957 - 04010, 09958 - 04010) or equivalents, remove the carrier retainer and adjusting plate washer.

Other models:
Using two screwdrivers, remove the carrier retainer.





c. Using a screwdriver, remove the O-ring from the carrier retainer.





4. Remove differential case. Take the differential case out of the carrier while lifting the ring gear side, as shown in the illustration.





5. Remove side bearing outer race (and adjusting plate washer).

Manual Transmission (M/T): Using a brass bar and hammer, remove the side bearing outer race.

Fig. 26 Removing Side Bearing Outer Race & Plate Washer:

Other models: Using SST 09950 - 60020 (09951 - 00710), 09950 - 70010 (09951 - 07150) or equivalents, and a press, remove the outer race and the adjusting plate washer.

6. Remove drive pinion, (oil slinger), spacer and companion flange, as follows:
a. Using a chisel and hammer, loosen the staked part of the nut.





b. Using SST 09229 - 55010 (except for the model M/T), 09330 - 00021 or equivalent (and a 36 mm deep socket wrench), remove the nut.





c. Using a press, remove the drive pinion with the rear bearing and spacer.

NOTICE: Be careful not to drop the drive pinion.

d. Remove the companion flange.
e. Remove the oil slinger (M/T) and spacer from the drive pinion.





7. Remove oil seal. Using SST 09308 - 00010 or equivalent, remove the oil seal.
8. Remove (oil slinger) and front bearing. Remove the oil slinger (except for M/T), and front bearing by hand.





9. Remove rear bearing from drive pinion. Using SST 09950 - 00020 or equivalent, and a press, remove the rear bearing from the drive pinion.





10. Remove front and rear bearing outer races and adjusting plate washer. Using a brass bar and hammer, remove the front and rear bearing outer races and adjusting plate washer from the differential carrier.

NOTE: Measure the adjusting plate washer thickness and make a note of it for reassembly.





11. Remove left and right hand side bearings. Using SST 09550 - 10012 (09558 - 10010), 09950 - 40010 (09951 - 04010, 09952 - 04010, 09953 - 04020, 09954 - 04010, 09955 - 04070, 09957 - 04010, 09958 - 04010) or equivalents, remove the left and right hand side bearings from the differential case.
12. Remove ring gear, as follows:





a. Place matchmarks on the ring gear and differential case.
b. Remove the ring gear set bolts.
c. Using a plastic hammer, tap on the ring gear to separate it from the differential case.

13. Conventional differential: Disassemble differential case, as follows:





NOTICE: Do not disassemble the differential case except conventional differential.





a. Using a pin punch and hammer, remove the straight pin.
b. Remove these parts from the differential case.

- Pinion shaft.
- Differential pinion.
- Pinion thrust washer.
- Side gear.
- Side gears thrust washer.