Front Differential Carrier: Replacement

Replace companion flange dust deflector, if necessary :
1. Using SST and a press, remove the dust deflector.
  1. SST 09950-00020
    
    Fig 1: Pressing Dust Deflector Off
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new dust deflector. SST 09636-20010
  
  Fig 2: Pressing Dust Deflector On
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Replace intermediate shaft No. 2, if necessary :
1. W/A.D.D.: Remove the clutch hub.
  1. Using a snap ring expander, remove the snap ring.
    
    Fig 3: Removing Snap Ring & Clutch Hub From Intermediate Shaft No. 2
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the clutch hub from the intermediate shaft No. 2.
2. Remove the oil seal.
  Using SST, remove the oil seal from the differential tube.
  1. SST 09308-00010
    
    Fig 4: Removing Intermediate Shaft No. 2 Oil Seal From Tube
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the intermediate shaft No. 2
  1. Using needle nose pliers, remove the snap ring.
  2. Remove the shaft from the differential tube.
4. Remove the intermediate shaft No. 2 bearing.
  1. Using a snap ring expander, remove the snap ring.
  2. Using SST, a brass bar and press, remove the bearing.
    1. SST 09950-00020
      
      Fig 5: Pressing Intermediate Shaft No. 2 Bearing Out
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install a new intermediate shaft No.2 bearing.
  1. Using SST and a press, install a new bearing.
    1. SST 09309-37010
      
      Fig 6: Pressing Intermediate Shaft No. 2 Bearing In
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using a snap ring expander, install the snap ring.
6. Install the intermediate shaft No.2
  1. Install the shaft into the differential tube.
  2. Using needle nose pliers, install the snap ring.
7. Install a new oil seal.
  1. Using SST, install a new oil seal.
    1. SST 09223-15020
      
      Fig 7: Installing Oil Seal
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Oil seal drive in depth: 5.5 mm (0.217 in.)
  2. Coat the oil seal lip with MP grease.
8. W/A.D.D.: Install the clutch hub.
  1. Install the clutch hub to the intermediate shaft No.2.
    
    Fig 8: Installing Clutch Hub
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using snap ring pliers, install the snap ring.