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Home >> Lexus Truck >> 2012 >> RX 350 AWD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Differential Carrier >> Service and Repair >> Overhaul >> Disassembly

Disassembly





AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: DISASSEMBLY

HINT
Use an overhaul stand as necessary.

1. SEPARATE ELECTRO MAGNETIC CONTROL COUPLING WIRE HARNESS

(a) Disengage the claw and separate the electro magnetic control coupling wire harness form the 2 clamps.





2. REMOVE CONNECTOR BRACKET

(a) Remove the 3 bolts and 2 connector brackets from the rear differential carrier.





(b) Remove the 2 clamps from the 2 connector brackets.

3. REMOVE REAR DIFFERENTIAL FILLER PLUG

(a) Remove the rear differential filler plug and gasket.





4. INSPECT RUNOUT OF ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY

(a) Install a dial indicator and magnetic base perpendicular to the inner side of the electro magnetic control coupling sub-assembly as shown in the illustration.





(b) Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the vertical runout.

SST : 09564-32011

Maximum runout:

0.06 mm (0.00236 in.)

If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

(c) Install a dial indicator and magnetic base perpendicular to the electro magnetic control coupling sub-assembly as shown in the illustration.

(d) Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the lateral runout.

SST : 09564-32011

Maximum runout:

0.07 mm (0.00276 in.)

If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

5. REMOVE REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG

(a) Using a screwdriver, remove the rear differential carrier cover breather plug.





6. REMOVE ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY

(a) Remove the 4 bolts.





(b) Using a plastic hammer, lightly tap the electro magnetic control coupling sub-assembly to remove it from the rear differential carrier assembly.

7. REMOVE CONICAL SPRING WASHER

(a) Remove the conical spring washer from the rear differential carrier assembly.





Text in Illustration





8. REMOVE SPACER

(a) Remove the spacer from the rear differential carrier assembly.





Text in Illustration





9. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a ring gear tooth tip.





(b) Using SST, hold the drive pinion in place.

SST : 09556-16011

(c) Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

SST : 09564-32011

Backlash:

0.13 to 0.25 mm (0.00512 to 0.00984 in.)

NOTICE:
Measure at 3 or more areas on the circumference of the ring gear.

If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST and a torque wrench, inspect the differential drive pinion preload (starting torque) of the backlash between the differential drive pinion and differential ring gear.





SST : 09556-16011

Standard drive pinion preload:

1.5 to 2.5 N*m (16 to 25 kgf*cm, 14 to 22 in.*lbf)

HINT
For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

If the differential drive pinion preload is not within the specified range, adjust the differential drive pinion preload or repair as necessary.

11. INSPECT TOTAL PRELOAD

(a) Using SST and a torque wrench, inspect the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.

SST : 09556-16011





Standard total preload:

2.8 to 5.3 N*m (29 to 54 kgf*cm, 25 to 47 in.*lbf)

NOTICE:
For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

If the total preload is not within the specified range, adjust the total preload or repair as necessary.

12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Using SST, remove the 2 rear differential side gear shaft oil seals from the rear differential carrier assembly.





SST : 09308-00010

13. REMOVE DIAPHRAGM OIL SEAL

(a) Using SST, remove the diaphragm oil seal from the rear differential carrier assembly.





Text in Illustration





SST : 09308-00010

14. REMOVE REAR DRIVE PINION NUT

(a) Using SST and a hammer, unstake the rear drive pinion nut.





Text in Illustration





SST : 09930-00010

NOTICE:
* Use SST with the tapered part facing against the shaft.
* Do not modify the SST tip with a grinder or equivalent.
* Fully unstake the rear drive pinion nut.

(b) Using SST, hold the differential drive pinion in place and remove the rear drive pinion nut from the differential drive pinion.

SST : 09556-16011

SST : 09564-16020





15. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using SST, remove the rear drive pinion front tapered roller bearing (inner race) from the differential drive pinion.





Text in Illustration





SST : 09556-40010

16. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

(a) Remove the 10 bolts from the rear differential carrier assembly.





(b) Using a brass bar and a hammer, disengage the 2 pins and remove the differential side bearing retainer from the rear differential carrier assembly.





NOTICE:
Set the brass bar on the ribbed part of the differential side bearing retainer.

17. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY

(a) Remove the rear differential case assembly from the rear differential carrier.





18. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(a) Remove the 2 bolts and rear differential breather plug oil deflector from the rear differential carrier.





19. REMOVE DIFFERENTIAL DRIVE PINION

(a) Remove the differential drive pinion from the rear differential carrier.





20. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Remove the rear differential drive pinion oil slinger from the differential drive pinion.





21. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Remove the rear differential drive pinion bearing spacer from the differential drive pinion.





22. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST and a press, press out the rear drive pinion rear tapered roller bearing (inner race) from the differential drive pinion.





SST : 09950-00020

NOTICE:
* If the differential drive pinion or differential ring gear is damaged, replace them both.
* Do not drop the differential drive pinion.

(b) Remove the rear differential drive pinion plate washer.

23. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using SST, remove the rear drive pinion front tapered roller bearing (outer race) from the rear differential carrier.





Text in Illustration





SST : 09387-00041

09387-01030

09387-01040

SST : 09387-02020

24. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using a brass bar and a hammer, lightly and uniformly tap out the rear drive pinion rear tapered roller bearing (outer race) from the rear differential carrier.





NOTICE:
Set the brass bar on the notch.

25. REMOVE REAR DIFFERENTIAL CASE BEARING (for LH Side)

(a) Using SST and a press, remove the rear differential case bearing (LH side outer race) and rear differential side gear shaft plate washer from the differential side bearing retainer.





Text in Illustration





SST : 09950-60010

09951-00540

SST : 09950-70010

09951-07100

26. REMOVE REAR DIFFERENTIAL CASE BEARING (for RH Side)

(a) Using SST and a press, remove the rear differential case bearing (RH side outer race) and rear differential side gear shaft plate washer from the rear differential carrier.





Text in Illustration





SST : 09950-60010

09951-00590

SST : 09950-70010

09951-07100

27. REMOVE STRAIGHT PIN

(a) Remove the 4 straight pins from the rear differential carrier.





28. REMOVE REAR DIFFERENTIAL CASE BEARING (for LH Side)

HINT
Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.

(a) Using SST, remove the rear differential case bearing (LH side inner race) from the rear differential case sub-assembly.





Text in Illustration





SST : 09950-40011

09951-04020

09952-04010

09953-04020

09954-04010

09955-04011

09957-04010

09958-04011

SST : 09950-60010

09951-00340

NOTICE:
Before using the SST center bolt, apply grease to its threads and tip.

HINT
If the race remains on the rear differential case sub-assembly, repeat the step above to remove the race.

29. REMOVE REAR DIFFERENTIAL CASE BEARING (for RH Side)

HINT
Perform this step only when replacing the rear differential case bearing or rear differential case sub-assembly.

(a) Using SST, remove the rear differential case bearing (RH side inner race) from the rear differential case sub-assembly.





Text in Illustration





SST : 09950-40011

09951-04020

09952-04010

09953-04020

09954-04010

09955-04061

09957-04010

09958-04011

SST : 09950-60010

09951-00370

NOTICE:
Before using the SST center bolt, apply grease to its threads and tip.

HINT
If the race remains on the rear differential case sub-assembly, repeat the step above to remove the race.

30. REMOVE DIFFERENTIAL RING GEAR

(a) Place matchmarks on the rear differential case sub-assembly and differential ring gear.





Text in Illustration





(b) Remove the 12 ring gear set bolts.

(c) Using a plastic hammer, lightly and uniformly tap the outer circumference of the differential ring gear to remove it from the rear differential case sub-assembly.

NOTICE:
* Do not drop the differential ring gear.
* If the differential drive pinion or differential ring gear is damaged, replace them both.

HINT
If it is difficult to remove, tap the outer circumference of the differential ring gear using a brass bar and a hammer.

31. INSPECT DIFFERENTIAL PINION AND SIDE GEAR

(a) Check the differential pinion gears and differential side gears for wear.

If the differential pinion gears and differential side gears are damaged, replace the rear differential case sub-assembly.

32. INSPECT DIFFERENTIAL CASE

(a) Check the differential case for cracks or damage.

If the differential case is damaged, replace the rear differential case sub-assembly.
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