Front Differential Carrier Assembly Disassembly

Drivetrain. Land Cruiser. Urj200, 202 Grj200 Vdj200
Axle And Differential. Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. REMOVE DIFFERENTIAL EXTENSION FLANGE TUBE

  2. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

  3. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT

  4. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

  5. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

  6. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

  7. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER

  8. REMOVE FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

  9. REMOVE DIFFERENTIAL DRIVE PINION

  10. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING

  11. REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

  12. REMOVE FRONT DIFFERENTIAL UNION

  13. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

  14. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

  15. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING

  16. REMOVE FRONT DIFFERENTIAL CASE BEARING

  17. REMOVE DIFFERENTIAL RING GEAR

  18. REMOVE FRONT DIFFERENTIAL CASE BEARING

  19. DISASSEMBLE DIFFERENTIAL CASE

  20. INSPECT DIFFERENTIAL GEAR KIT

  21. INSPECT FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

  22. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

  23. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH

  24. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING

  25. REMOVE FRONT DIFFERENTIAL CARRIER STRAIGHT PIN

  26. REMOVE FRONT DIFFERENTIAL TUBE STRAIGHT PIN

Front Differential Carrier Assembly -- Disassembly



1. REMOVE DIFFERENTIAL EXTENSION FLANGE TUBE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts.

  1. Using a plastic-faced hammer, remove the differential tube.



2. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST, tap out the oil seal.

    SST
    09308-00010


3. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST and a hammer, unstake the nut.

    SST
    09930-00010


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST to hold the companion flange, remove the nut.

    SST
    09330-00021(09330-00030)


4. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST, remove the companion flange from the differential carrier.

    SST
    09950-30012(09951-03010,09953-03010,09954-03010,09955-03030,09956-03020)


5. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST, remove the oil seal.

    SST
    09308-10010


6. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER


7. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Remove the bolts labeled B and front differential front support assembly LH.

  1. Remove the bolts labeled A.

  1. Using a plastic-faced hammer, tap out the bearing retainer.



8. REMOVE FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

  1. Remove the differential case from the differential carrier.



9. REMOVE DIFFERENTIAL DRIVE PINION


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Set the differential carrier to an overhaul stand as shown in the illustration.

  1. Using a press, press out the drive pinion.

    NOTICE:
    Do not drop the drive pinion.


10. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING

  1. Remove the bearing (inner race) from the differential carrier.



11. REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and oil deflector.



12. REMOVE FRONT DIFFERENTIAL UNION


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the front differential union from the differential carrier.



13. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST and a press, press out the bearing (inner race) from the drive pinion.

    SST
    09950-00020
    If the drive pinion or ring gear is damaged, replace them as a set.


14. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a brass bar and hammer, tap out the bearing (outer race) and washer.



15. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST and a hammer, tap out the bearing (outer race) from the differential carrier.

    SST
    09950-70010(09951-07100)
    09950-60010(09951-00450)
    09950-60020(09951-00710,09952-06010)


16. REMOVE FRONT DIFFERENTIAL CASE BEARING
HINT:
  1. Measure the plate washer and note its thickness.
  2. Tag the bearing outer races to show the location for reassembly.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST and a press, press out the bearing (outer race) and plate washer from the bearing retainer.

    SST
    09950-60020(09951-00680)
    09950-70010(09951-07150)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST and a press, press out the bearing (outer race) and plate washer from the differential carrier.

    SST
    09950-60020(09951-00680)
    09950-70010(09951-07150)


17. REMOVE DIFFERENTIAL RING GEAR


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Place matchmarks on the ring gear and differential case.

  1. Remove the 12 bolts.

  1. Using a plastic-faced hammer, tap on the ring gear to disconnect it from the differential case.



18. REMOVE FRONT DIFFERENTIAL CASE BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST, remove the 2 bearings (inner race).

    SST
    09950-60010(09951-00390)
    09950-40011(09951-04020,09952-04010,09953-04030,09954-04010,09955-04061,09957-04010,09958-04011)
    HINT:
    Fix the claws of SST into the notch in the differential case assembly.


19. DISASSEMBLE DIFFERENTIAL CASE


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using a pin punch and hammer, tap out the straight pin.

  1. Remove these parts from the differential case assembly.

    1. 2 differential side gears

    2. 2 differential side gear thrust washers

    3. Differential pinion shaft

    4. 2 differential pinion gears

    5. 2 differential pinion gear thrust washers



20. INSPECT DIFFERENTIAL GEAR KIT

  1. Check that there is no damage to the pinion gears and side gears.
    If a pinion gear and/or side gear is damaged, replace the differential gear kit.



21. INSPECT FRONT NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

  1. Check that the differential case is not damaged.
    If the differential case is damaged, replace it.



22. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST, tap out the oil seal from the flange tube.

    SST
    09308-00010


23. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a snap ring pliers, remove the snap ring.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a plastic-faced hammer, tap out the side gear shaft.



24. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a snap ring expander, remove the snap ring.



    Land Cruiser. Urj200, 202 Grj200 Vdj200.Axle And Differential.Axle System.Front Differential Carrier Assembly Disassembly

  1. Using SST and a press, press out the bearing.

    SST
    09950-00020
    09950-70010(09951-07100)
    09950-60010(09951-00450)
    NOTICE:
    Do not damage the bearing.


25. REMOVE FRONT DIFFERENTIAL CARRIER STRAIGHT PIN


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the straight pins from the bearing retainer.



26. REMOVE FRONT DIFFERENTIAL TUBE STRAIGHT PIN


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the straight pins from the bearing retainer.