Front Diff Disassembly

[cj80cruiser]

I need some help figuring out what bolts need to be taken out for the front 3rd to separate. I was looking through the online fsm but it's not 100% clear for me at the moment.

I removed the 10 14mm bolts already. From what I read it's necessary to remove the 6 torx head bolts to separate the 2 halves.

E14 torx socket is recommended but can I get away with a 12pt socket or ratchet wrench? If you have any suggestions or tips about what I'm doing please let me know.

 

[4-Ripcord]

http://www.ncttora.com/fsm/1996/SIL...toypdf/02rmsour/2002/024runne/sa/fdc/comp.pdf

http://www.ncttora.com/fsm/1996/SIL...toypdf/02rmsour/2002/024runne/sa/fdc/disa.pdf

Either of those help?


EDIT: nvm just saw you already read the FSM. IDK then..

 

[JWaldz]

Hmm, I've never cracked open a front.. Only a rear diff. If no one has any good info here I would ask Chase over at East Coast Gear Supply. I guarantee you he knows.

 

[Rockdawg84]

I need some help figuring out what bolts need to be taken out for the front 3rd to separate. I was looking through the online fsm but it's not 100% clear for me at the moment.

I removed the 10 14mm bolts already. From what I read it's necessary to remove the 6 torx head bolts to separate the 2 halves.

E14 torx socket is recommended but can I get away with a 12pt socket or ratchet wrench? If you have any suggestions or tips about what I'm doing please let me know.

Buy the torx socket. It will cost the same as buying new bolts from Toyota. Guess how I know. Lol. And all I was doing was changing over the axle tubes. Good luck. I think j-money has dug into a front diff but I'm not sure. Maybe shoot him a pm

 

[cj80cruiser]

Buy the torx socket. It will cost the same as buying new bolts from Toyota. Guess how I know. Lol. And all I was doing was changing over the axle tubes. Good luck. I think j-money has dug into a front diff but I'm not sure. Maybe shoot him a pm

Once I take those out that should open it up right? I noticed a single 19mm (atleast it looked like a 19mm) as well. Does that need to be removed?

 

[cj80cruiser]

Hmm, I've never cracked open a front.. Only a rear diff. If no one has any good info here I would ask Chase over at East Coast Gear Supply. I guarantee you he knows.

Taking the front diff out wasn't fun at all. I actually ended up unbolting the motor mounts to get it out....probably was an easier way but I couldn't figure it out and I was wasting time trying.

 

[J-money$$$]

Buy the torx socket. It will cost the same as buying new bolts from Toyota. Guess how I know. Lol. And all I was doing was changing over the axle tubes. Good luck. I think j-money has dug into a front diff but I'm not sure. Maybe shoot him a pm

Yes sir I sure have. More than once.

THere are a few options, however it is best to just go over to harbor freight and buy the proper sockets. YOU WILL STRIP the torx bolts without it. they are torqued down to 70 ft lbs or something like that. I ended up also buying new bolts with regular hex heads to replace all of those with.

SO your on the right track. I can't perfectly remember if it was necessary but i removed the add actuator first, then the 4 torx that hold the add tube to the diff. Once you get all that off you will see the stub shaft stuck into the passenger side of the diff. This needs to come out before splitting the case. Its held in exactly like your cv joints. SO take a couple pry bars and pop it out. BE CAREFUL i broke the snapring on this last time.

Once thats take the rest of the bolts out and out tap the case apart. do this on the ground or something because the carrier with the ring gear will just fall out. Install is the same just backwards. Its actually a pretty diff to work on.

 

[scottyb]

Yeah, you need that torx socket. Like Rockdawg84, I damaged the torx bolts trying to get them out with 12pt sockets... Had to go get the right tool and hammer the torx socket on the damaged bolt.

If I remember correctly, you just need to take out 4 of the torx bolts. And obviously you need to take out all the bolts between the 2 cases as well. Then there is a stub shaft that connects the passenger side, side gear to the ADD tube. It is attached like a cv axle with the c clip. I ended up getting a screw driver and managed to get it right on the edge of the stub shaft from inside the passenger side case. One hit with a little sledge and it slid out.