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Home >> Lexus >> 2012 >> IS 250 AWD V6-2.5L (4GR-FSE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Differential Carrier >> Service and Repair >> Overhaul >> Differential Carrier Assembly >> Disassembly

Disassembly





DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE): DISASSEMBLY

1. REMOVE REAR DIFFERENTIAL BREATHER PLUG

(a) Remove the breather plug from the differential carrier cover.





2. REMOVE REAR DIFFERENTIAL CARRIER COVER

(a) Remove the 8 bolts from the differential carrier cover.





(b) Using a brass bar and a hammer, lightly tap the rib of the side bearing retainer to remove it.





NOTICE:
Do not damage the sealing surface of the differential carrier.

3. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(a) Remove the bolt and oil deflector from the differential carrier cover.





4. SECURE REAR DIFFERENTIAL CARRIER

(a) Set the differential carrier to an overhaul stand, etc., as shown in the illustration.





5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Differential Carrier Assembly

6. INSPECT DIFFERENTIAL RING GEAR BACKLASH Differential Carrier Assembly

7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Differential Carrier Assembly

8. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH Differential Carrier Assembly

9. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE Differential Carrier Assembly

10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD Differential Carrier Assembly

11. INSPECT TOTAL PRELOAD Differential Carrier Assembly

12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Using SST, remove the 2 oil seals.





SST : 09308-00010

13. REMOVE REAR DRIVE PINION NUT

(a) Using SST and a hammer, unstake the staked part of the drive pinion nut.





SST : 09930-00010

NOTICE:
* Be sure to use SST with the tapered surface facing the shaft.
* Do not grind the tip of the SST with a grinder, etc.
* Completely loosen the staked part of the nut when removing it.
* Do not damage the threads of the drive pinion.

(b) Using SST to hold the flange, remove the drive pinion nut.





SST : 09330-00021

14. REMOVE REAR DRIVE PINION COMPANION FLANGE

(a) Using SST, remove the companion flange.





SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03030

NOTICE:
Apply grease to the threads and tip of the SST center bolt before use.

15. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

HINT
Perform this procedure only when the dust deflector is damaged.

(a) Using SST and a press, remove the dust deflector.





SST : 09950-00020

SST : 09950-60010

09951-00380

SST : 09950-70010

09951-07100

NOTICE:
Do not drop the companion flange.

16. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

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





SST : 09308-00010

17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Remove the drive pinion oil slinger.





18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

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





SST : 09556-22010

NOTICE:
Apply grease to the threads and tip of the SST center bolt before use.

19. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Remove the drive pinion bearing spacer.





20. REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Put matchmarks on either set of the bearing cap and differential carrier.





(b) Remove the 4 bolts and 2 bearing caps.

NOTICE:
Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.

(c) Using SST and a hammer, remove the 2 side gear shaft plate washers.





SST : 09504-22011

NOTICE:
Put identification marks on the side gear shaft plate washer to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

HINT
Measure the thickness of the plate washers and note it.

(d) Remove the differential case assembly and the case bearing outer races LH and RH from the differential carrier.





NOTICE:
* Do not damage the differential case bearing or ring gear.
* Put identification marks on the case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

21. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

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

(b) Using SST and a press, remove the inner race of the rear drive pinion rear tapered roller bearing from the drive pinion.





SST : 09950-00020

NOTICE:
Do not drop the drive pinion.

HINT
If either the drive pinion or ring gear is damaged, replace both as a set.

(c) Remove the drive pinion plate washer from the drive pinion.

HINT
Measure the thickness of the plate washer and note it.

(d) Using a brass bar and a hammer, remove the outer race of the rear drive pinion front tapered roller bearing from the differential carrier.





NOTICE:
Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.

22. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using a brass bar and a hammer, remove the outer race of the rear drive pinion rear tapered roller bearing from the differential carrier.





NOTICE:
Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.

23. REMOVE DIFFERENTIAL RING GEAR

(a) Hold the differential case in a vise between aluminum plates.





NOTICE:
Do not overtighten the vise.

(b) Put matchmarks on the ring gear and differential case.

(c) Using a chisel and a hammer, unstake the 5 lock plates.

(d) Remove the 10 ring gear set bolts and 5 lock plates.





(e) Using a plastic hammer, tap on the ring gear to separate it from the differential case.





HINT
Use cloth to prevent damage to the ring gear teeth.

24. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY Differential Carrier Assembly

25. REMOVE REAR DIFFERENTIAL CASE BEARING

HINT
Perform this procedure only when replacing the case bearing or differential case.

(a) Hold the differential case in a vise between aluminum plates.





NOTICE:
Do not overtighten the vise.

(b) Using SST, remove the case bearing inner races LH and RH from the differential case.

SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04061

09957-04010

09958-04011

SST : 09950-60010

09951-00480

09951-00350

09952-06010

NOTICE:
* Do not deform the bearing cage if the bearing is to be reused.
* Hook the SST claw from the dent of the differential case to the bearing inner race.
* Apply grease to the threads and tip of the SST center bolt before use.
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