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Home >> Lexus >> 2012 >> IS 350 AWD V6-3.5L (2GR-FSE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Differential Carrier >> Service and Repair >> Overhaul >> Differential Carrier Assembly >> Reassembly >> Part 1

Part 1





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

1. INSTALL DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of the differential case and ring gear.





(b) Clean the differential ring gear set bolt hole.

(c) Heat the ring gear to approximately 100°C (212°F) in boiling water.

CAUTION:
Use thick gloves to protect your hands as the ring gear is hot.

(d) Carefully take the ring gear out of the boiling water.

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

NOTICE:
Do not overtighten the vise.

(f) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.





(g) Align the matchmarks on the ring gear and the differential case.

(h) After the ring gear has cooled sufficiently, install 10 new ring gear set bolts to which thread lock has been applied.

Thread lock:

Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent

NOTICE:
New ring gear set bolts should be used every time the ring gear is installed.

(i) Torque the 10 set bolts uniformly, a little at a time.





Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)

(j) Tighten the bolts further by 60° to 90°.





NOTICE:
Tighten diagonally opposite bolts in pairs.

2. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a press, install the case bearing inner races LH and RH to the differential case.





SST : 09950-60010

09951-00560

09951-00570

SST : 09950-70010

09951-07100

NOTICE:
* Do not apply hypoid gear oil to a new bearing.
* Do not deform the bearing cage. Set SST to the center of the differential case.
* If the bearing is replaced, replace it and its outer race as a set.

3. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST and a press, press in the rear drive pinion rear tapered roller bearing inner race to the drive pinion.





SST : 09316-60011

09316-00031

SST : 09612-10093

09613-22011

NOTICE:
Do not apply hypoid gear oil to a new bearing.

HINT
Disassemble SST (09613-22011), and only use the pipe part.

(b) Using SST and a press, press in the rear drive pinion rear tapered roller bearing outer race and plate washer.





SST : 09255-10012

SST : 09950-70010

09951-07200

NOTICE:
Do not apply hypoid gear oil to a new bearing.

HINT
Select a plate washer of the same thickness as the one removed.

4. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, press in the rear drive pinion front tapered roller bearing outer race to the differential carrier.





SST : 09950-60020

09951-00710

SST : 09950-70010

09951-07100

NOTICE:
Do not apply hypoid gear oil to a new bearing.

(b) Install the rear drive pinion front tapered roller bearing inner race to the differential carrier.





NOTICE:
Do not apply hypoid gear oil to a new bearing.

5. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

HINT
Perform this procedure only when replacing the dust deflector.

(a) Using SST and a press, insert a new dust deflector into the companion flange.





SST : 09316-60011

09316-00011

NOTICE:
* Slowly press in the dust deflector but not press it excessively.
* If any burrs remain after pressing in the deflector, remove them.

6. INSTALL DIFFERENTIAL DRIVE PINION

(a) Using SST and a press, install the differential drive pinion.





SST : 09316-60011

09316-00011

SST : 09608-04031

HINT
Install the spacer and oil seal after adjusting the tooth contact pattern.

7. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Install the drive pinion oil slinger.





8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST, install the companion flange.





SST : 09950-30012

09951-03010

09954-03010

09956-03060

09955-03040

NOTICE:
* Install the companion flange so that there is a slight looseness on the drive pinion because the bearing spacer is not yet installed.
* Apply grease to the threads and tip of SST center bolt before use.

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





(c) Using SST to hold the flange, torque the drive pinion nut.

SST : 09229-55010

SST : 09330-00021

Torque:

490 N*m (5000 kgf*cm, 361 ft.*lbf) or less

NOTICE:
* Apply hypoid gear oil LSD to the nut and the threads of the drive pinion.
* As there is no bearing spacer, tighten the nut a little at a time and do not overtighten it.

HINT
Tighten the nut to approximately 100 N*m (1020 kgf*cm, 74 ft.*lbf), and tighten it further while checking the preload.

(d) Turn the bearing clockwise and counterclockwise several times to stabilize it.





(e) Using SST and a torque wrench, measure the preload.

Drive pinion preload (at starting):

New bearing
1.12 to 1.70 N*m (11.4 to 17.3 kgf*cm, 9.9 to 15.0 in.*lbf)

Reused bearing
0.40 to 0.70 N*m (4.1 to 7.1 kgf*cm, 3.5 to 6.2 in.*lbf)

NOTICE:
Record the preload for total preload measurement.

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

9. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Insert the differential case from the ring gear tooth side to install the differential case.





NOTICE:
Do not damage the case bearing and ring gear.

10. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a hammer, tap in the ring gear tooth side case bearing outer race.





SST : 09608-32010

SST : 09950-70010

09951-07200

NOTICE:
Do not apply hypoid gear oil to a new bearing.

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 with 2 bolts.





SST : 09571-50010

(c) Tighten SST bolt (A) until SST disc lightly touches the case bearing outer race.

(d) Using SST and a hammer, tap in the ring gear back surface side case bearing outer race.





SST : 09608-32010

SST : 09950-70010

09951-07200

NOTICE:
Do not apply hypoid gear oil to a new bearing.

HINT
Tap in the case bearing outer race until it touches the case bearing inner race roller bearing.

11. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING

(a) Using snap ring pliers, install the thinnest side gear shaft snap ring on the back surface of the ring gear.





HINT
* If the final gear set (drive pinion and ring gear) and case bearing are new, select a thinner side gear shaft snap ring and install it.
* If the final gear set (drive pinion and ring gear) and case bearing are reused, install a side gear shaft snap ring with the same thickness as the removed one.

(b) Install a dial indicator to the differential carrier.





(c) Tighten SST bolt to alter the shape of the differential carrier by approximately 0.1 mm (0.004 in.).

SST : 09571-50010

NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).

HINT
* Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
* Tighten SST bolt to apply the preload to the case bearing.

(d) Turn the ring gear clockwise and counterclockwise several times.

(e) Using a dial indicator, measure the backlash of the ring gear at 3 positions.





Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

NOTICE:
The difference between the maximum and minimum values must be within 0.05 mm (0.002 in.).

HINT
* Record the measured backlash to use as a reference for selecting a side gear shaft snap ring.
* If the backlash is not within the specified range, replace the side gear shaft snap ring on the ring gear tooth side with a snap ring of different thickness as described in the following procedure.
* Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring.

(f) Loosen SST bolt and separate SST disc from the case bearing outer race on the ring gear tooth side.

(g) Using SST and a hammer, create a clearance between the side gear shaft snap ring on the ring gear back surface side and case bearing outer race.





SST : 09608-32010

SST : 09950-70010

09951-07200

(h) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.





(i) Using snap ring pliers, install a side gear shaft snap ring with a different thickness.





HINT
When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash also changes by 0.02 mm (0.0008 in.).

Snap ring thickness





(j) Using a plastic hammer, lightly tap the ring gear tooth side of the differential carrier.





(k) Install a dial indicator to the differential carrier.





(l) Tighten SST bolt to alter the shape of the differential carrier approximately 0.1 mm (0.004 in.).

SST : 09571-50010

HINT
Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side oil seal is tapped in.

(m) Using a dial indicator, measure the backlash of the ring gear at 3 positions.





Backlash:

0.08 to 0.13 mm (0.0031 to 0.0051 in.)

(n) If the backlash is not within the specified range, replace the side gear shaft snap ring on the back surface of the ring gear with one of a different thickness.

HINT
* Record the measured backlash to use as a reference for selecting a side gear shaft snap ring.
* Inspect tooth contact to use the result as a reference for selecting a side gear shaft snap ring.
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