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Home >> Lexus >> 2009 >> IS 350 V6-3.5L (2GR-FSE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Differential Carrier >> Service and Repair >> Overhaul >> Reassembly >> Part 2

Part 2








DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY (for 2GR-FSE): REASSEMBLY

REASSEMBLY (Continued)

23. REMOVE DIFFERENTIAL DRIVE PINION





(a) Using a press, remove the drive pinion from the differential carrier.
NOTE:
Do not drop the drive pinion.

24. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING





(a) Remove the rear drive pinion front tapered roller bearing from the differential carrier.
25. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER





(a) Install a new drive pinion bearing spacer to the drive pinion.
HINT:
The bearing spacer can be installed in either direction.

26. INSTALL DIFFERENTIAL DRIVE PINION





(a) Using SST and a press, install the differential drive pinion to the differential carrier.
SST: 09316-60011
09316-00011
09316-00041
SST: 09608-04031
27. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER





(a) Install the differential drive pinion oil slinger to the differential drive pinion.
28. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL





(a) Using SST and a hammer, install a new oil seal.
SST: 09316-60011
09316-00011
SST: 09710-30012
09710-04101
Oil seal installation depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)
(b) Apply MP grease to the oil seal lip.
29. INSTALL REAR DRIVE PINION COMPANION FLANGE





(a) Using SST, install the companion flange to the drive pinion.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09956-03060
09955-03040
NOTE:
Apply grease to the threads and tip of the SST center bolt before use.

(b) Coat the threads of a new drive pinion nut with hypoid gear oil LSD.





(c) Use SST to hold the flange and torque the drive pinion nut.
SST: 09229-55010
SST: 09330-00021
SST: 09950-30012
09955-03040
Torque:
490 N*m (5,000 kgf*cm, 361 ft.*lbf) or less
- Do not tighten excessively, otherwise the threads will be stripped.
- Apply hypoid gear oil LSD to the threads of the nut and drive pinion.
HINT:
Tighten the nut to approximately 100 N*m (1,020 kgf*cm, 74 ft.*lbf), then tighten it further while observing the preload.

30. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY





(a) Insert the differential case from the ring gear tooth side.
NOTE:
Do not damage the case bearing inner race or ring gear.

31. INSTALL REAR DIFFERENTIAL CASE BEARING





(a) Using SST and a hammer, install the ring gear tooth side case bearing outer race.
SST: 09608-32010
SST: 09950-70010
09951-07200
HINT:
Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.





(b) Install SST to the differential carrier.
SST: 09571-50010
(c) Tighten the SST bolt until the SST disc lightly touches the case bearing outer race.





(d) Using SST and a hammer, install the ring gear back surface side case bearing outer race.
SST: 09608-32010
SST: 09950-70010
09951-07200
HINT:
Tap in the case bearing outer race until it touches the case bearing inner race roller.

32. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING





(a) Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.
HINT:
Use the side gear shaft snap ring installed when performing tooth contact adjustment.





(b) Set a dial indicator on the differential carrier.
(c) Tighten the SST bolt to alter the shape of the differential carrier by approximately 0.1mm (0.004 in.).
NOTE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more that 0.2 mm (0.008 in.).





(d) Using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side.
HINT:
Use the side gear shaft snap ring installed when performing tooth contact adjustment.





(e) Remove the dial indicator and tap the differential carrier on the ring gear tooth side using a plastic hammer to stabilize the case bearing.





(f) Remove the SST.
33. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD





(a) Using SST and a torque wrench, measure the preload.
SST: 09229-55010
Drive pinion preload (at starting):
New bearing
1.22 to 1.80 N*m (12.4 to 18.4 kgf*cm, 10.7 to 16.0 in.*lbf)
Reused bearing
0.50 to 0.80 N*m (5.0 to 8.2 kgf*cm, 4.4 to 7.1 in.*lbf)
- If the preload is less than the specified minimum value, check the preload while retightening the drive pinion nut by 5 to 10°.
Torque:
490 N*m (5,000 kgf*cm, 361 ft.*lbf) or less
- If the preload is less than the specified minimum value even when the tightening torque of the drive pinion nut is greater than the specified maximum value, loosen the nut and check that the threads of the drive pinion nut and drive pinion are not stripped.
- If the threads are not stripped, replace the bearing spacer. Apply hypoid gear oil LSD to the threads of the drive pinion and repeat the procedure.

34. INSPECT TOTAL PRELOAD Testing and Inspection
35. INSPECT DIFFERENTIAL RING GEAR BACKLASH Testing and Inspection
36. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION Testing and Inspection
37. INSTALL REAR DRIVE PINION NUT





(a) Using SST and a hammer, stake the drive pinion nut.
SST: 09930-00010
38. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL





(a) Using SST and a hammer, install 2 new oil seals.
SST: 09223-15030
SST: 09950-70010
09951-07200
Oil seal installation depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)
- Make sure to check the identification marks on the oil seals before installation because the parts numbers differ between the left and right sides.
- To ensure a proper seal, evenly tap in the rear differential side gear shaft oil seal.
- After installing oil seal, tap it in until surface is flush with the rear differential carrier.

(b) Apply MP grease to the oil seal lips.
39. INSTALL REAR DIFFERENTIAL DRAIN PLUG
(a) Using a hexagon wrench (10 mm), install the differential drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
40. REMOVE REAR DIFFERENTIAL CARRIER





(a) Remove the differential carrier from the overhaul attachment.
NOTE:
Clean the fitting surface between the differential carrier and carrier cover.

41. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR





(a) Clean the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with white gasoline or equivalent.
NOTE:
Do not scratch the sealing surface.

(b) Install the rear differential breather plug oil deflector to the rear differential carrier cover.
Torque: 7.0 Nm (70 kgf-cm, 62 in-lbf)
42. INSTALL REAR DIFFERENTIAL CARRIER COVER





(a) Apply FIPG to the differential carrier at the position shown in the illustration.
FIPG:
08826-00090, THREE BOND 1281 or equivalent
- Apply the seal packing in a continuous bead, approximately 2 to 3 mm (0.08 to 0.12 in.) in diameter.
- Overlap the seal packing at least 10 mm at the beginning and the end of application.
- Install the differential carrier cover within 3 minutes of application.





(b) Install the differential carrier cover with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 35 ft-lbf)
NOTE:
Do not fill the differential with oil or drive immediately after installing the differential carrier cover. Allow at least one hour for the sealant to dry before filling the differential. Avoid sudden acceleration and deceleration for at least 12 hours after installation of parts using FIPG sealant.

43. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG





(a) Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft-lbf)
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