how to split the front diff?

74k30 · 12-02-2009, 02:13 AM

Im working on a 2001.5 tacoma front end. 2.7 motor and manual tranny if that makes a difference.
I have the diff out and on my work bench. Pulled the ten bolts out that hold the two halves together. There is an ADD drive gear on the passenger side of this diff (that is on the outside of the diff but mounted to it) that is holding this damn thing together.
This diff is eff'd. I've managed to get it far enough apart for pieces of gear teeth to spill out, but I can't get that damn gear off the passenger side thats in the way of giving me access to see the real damage.
Do I need a special "Toyota gear puller" or something?
Please help. I am a Chevy guy and don't know Toyotas. I am only doing this because my buddy who owns the truck is new to four wheelin and doesnt know anything yet. I'm trying to teach this kid how to work on trucks while learning a bit about some new stuff myself.
My Dana 60 front would never give me this much grief.
I don't know how you guys do it. please help me Toyota guys.

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hross14 · 12-02-2009, 06:32 AM

those front clam shell diffs are not rebuilt by many folks at all. Not even ZUK rebuilds them.....in all honestly--I would get one from a junk yard or get one built by Just Differentials.

You are not wrong to say they are a ROYAL PITA to rebuild....the rest of the diffs are your normal fair.

Price wise on an IFS diff should be pretty cheap since nobody really wants them. Most people do a SOLID AXLE SWAP (SAS) because the front gear is only 7.5" and cant handle larger tires (35").

Good luck

VSU_4runnin · 12-02-2009, 09:07 AM

merry christmas.. hope this helps
http://www.ttora.com/forum/showthread.php?t=145582

LarsDennert · 12-03-2009, 06:12 PM

I recall there being a flange area where you can pry open.

Here is an article I wrote some time ago. May help you.

http://www.4x4wire.com/toyota/4Runne...ifs_airlocker/

74k30 · 12-04-2009, 10:59 AM

Thanks for the helpful links, but what I still can't figure out is, how do you get the clamshell half off with that ADD gear still on there? I see in some of those pics that the ADD gear was still attached to the carrier after the clamshell half was off.

VSU_4runnin · 12-04-2009, 11:51 AM

i asked around.. we'll see if there are any answers

edit:
answer

Quote:

Originally Posted by gregers05

i should come off the same way it does without the gear/tube on there. really, the only way i have ever taken a front diff apart was with the tube assembly on there. i dont know why that would prevent it from coming apart?

answer 2

Quote:

Originally Posted by silvertoy

If I understand what he's askin....see the ring with the holes in it in this pic? That kinda holds that gear into the clamshell. Take 2 crowbars or a crowbar and a flat head screw driver and pry it apart. It's kinda like how you pry a CV axle out of the front diff with the C-clip. For re-assembly I put the clamshell back on the top (inside of clam facing downward) of what you see in the pic and hit it with a rubber hammer. It took me 2 tries to get it back on, 2nd time around I had to grease it up. You've got to hit it pretty hard too...which is hard to do when you feel like your gonna break it.

74k30 · 12-04-2009, 05:21 PM

Yeah, your right. It didn't look like prying it would help cuz that ring with the wholes in it is larger in diameter than the hole in the clamshell. But sure enough, just like the cv axle, it came out with enough persuasion from some prybars.
Now to the carrier out of the other half of the clam. Can't fit any prybars around the ring gear so I'm gonna try sticking the handle of a rubber mallet through the other side and pounding it out that way.
UPS man just dropped off the lockright so wish me luck.
Thanks for the help. I'll keep you updated.

74k30 · 12-07-2009, 11:43 AM

Well here's your update.
Got it all apart and ready to put the lockrite in.
Oops, ring gear is also shattered.
Oops, you can only get 4.30 ratio from the dealer for a price of $830.
Looks like we'll be replacing both axles with 4.56 for less than half that price.

VSU_4runnin · 12-09-2009, 11:33 AM

writeup? pics?

74k30 · 12-09-2009, 01:07 PM

I'll take some pics when I get back out in the garage. UPS man should be coming by today with two sets of 4.56 R&P's and and all the bearings. I'm very excited to tear into that rear end again. I was just in there last month putting in another lock rite.
Still looking for thrust washers though. They got pretty chewed up and according to the lock rite instructions, they are to be re-used in the front end.
Dude at the dealer said I need to determine the thickness of the ones I have so he knows which ones to sell me. I don't have a micrometer so I asked If he could mic em for me and he said no.
I thought dealers were all about customer service. What a dick.

12-02-2009, 06:32 AM	#2 (permalink)
hross14 Registered User Join Date: Feb 2006 Location: Austin Texas Posts: 1,401	those front clam shell diffs are not rebuilt by many folks at all. Not even ZUK rebuilds them.....in all honestly--I would get one from a junk yard or get one built by Just Differentials. You are not wrong to say they are a ROYAL PITA to rebuild....the rest of the diffs are your normal fair. Price wise on an IFS diff should be pretty cheap since nobody really wants them. Most people do a SOLID AXLE SWAP (SAS) because the front gear is only 7.5" and cant handle larger tires (35"). Good luck __________________ Yes, I said "country." America really is a nation, but you couldn't convince those who lead the Democratic and Republican Parties of that. Both parties now see America as nothing more than an economy, a marketplace, and not a sovereign nation. They don't see you and me as citizens of this great nation; they see us as units of labor, consumers and taxpayers. Yes, I am here to collect my 238$ worth of stock from AIG. "What do you mean a free market economy doesnt apply to the rich?"

12-03-2009, 06:12 PM	#4 (permalink)
LarsDennert Registered User Join Date: Apr 2003 Location: A stone's throw from the Rose Parade Posts: 207	I recall there being a flange area where you can pry open. Here is an article I wrote some time ago. May help you. http://www.4x4wire.com/toyota/4Runne...ifs_airlocker/ __________________ Lars www.LarsDennert.com '99 4Runner, Dual ARB lockers, TRD Tundra & FJ80 springs with long travel parts, 33's, Tundra Brakes, TRD Super Charger, Body Armor, Onboard Air, etc

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12-04-2009, 10:59 AM	#5 (permalink)
74k30 Registered User Join Date: Nov 2009 Posts: 7	Thanks for the helpful links, but what I still can't figure out is, how do you get the clamshell half off with that ADD gear still on there? I see in some of those pics that the ADD gear was still attached to the carrier after the clamshell half was off.

12-04-2009, 05:21 PM	#7 (permalink)
74k30 Registered User Join Date: Nov 2009 Posts: 7	Yeah, your right. It didn't look like prying it would help cuz that ring with the wholes in it is larger in diameter than the hole in the clamshell. But sure enough, just like the cv axle, it came out with enough persuasion from some prybars. Now to the carrier out of the other half of the clam. Can't fit any prybars around the ring gear so I'm gonna try sticking the handle of a rubber mallet through the other side and pounding it out that way. UPS man just dropped off the lockright so wish me luck. Thanks for the help. I'll keep you updated.

12-07-2009, 11:43 AM	#8 (permalink)
74k30 Registered User Join Date: Nov 2009 Posts: 7	Well here's your update. Got it all apart and ready to put the lockrite in. Oops, ring gear is also shattered. Oops, you can only get 4.30 ratio from the dealer for a price of $830. Looks like we'll be replacing both axles with 4.56 for less than half that price.

12-09-2009, 01:07 PM	#10 (permalink)
74k30 Registered User Join Date: Nov 2009 Posts: 7	I'll take some pics when I get back out in the garage. UPS man should be coming by today with two sets of 4.56 R&P's and and all the bearings. I'm very excited to tear into that rear end again. I was just in there last month putting in another lock rite. Still looking for thrust washers though. They got pretty chewed up and according to the lock rite instructions, they are to be re-used in the front end. Dude at the dealer said I need to determine the thickness of the ones I have so he knows which ones to sell me. I don't have a micrometer so I asked If he could mic em for me and he said no. I thought dealers were all about customer service. What a dick.