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Home >> Lexus >> 2012 >> LS 460 AWD V8-4.6L (1UR-FSE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Differential Carrier >> Service and Repair >> Overhaul >> Front Differential Carrier Assembly >> Reassembly >> Part 1

Part 1





DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for AWD): REASSEMBLY

1. INSTALL DIFFERENTIAL RING GEAR

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

(b) 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.

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

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





HINT
Align the matchmarks, differential case bolt holes and ring gear screw holes.

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





NOTICE:
Do not overtighten the vise.

(f) Apply adhesive to the threads and flanges of 10 new ring gear set bolts.





Torque : 97 Nm (989 kgf-cm, 72 ft-lbf)

Adhesive:

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

NOTICE:
* Tighten the bolts after the ring gear has sufficiently cooled down.
* Install the differential case bolts by tightening diametrically opposite pairs uniformly in several passes.

2. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING OUTER RACE

(a) Using SST, a bolt, nut, and washer, install the bearing outer race to the differential carrier.

SST : 09950-60020

09951-00730

09951-00810





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

HINT
If there are not enough threads, add another SST accordingly.

3. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING OUTER RACE

(a) Install the adjust shim to the differential carrier.





HINT
Select a adjusting shim of the same thickness as the one removed.

(b) Using SST, a bolt, nut, and washer, install the bearing outer race to the differential carrier.

SST : 09950-60020

09951-00730

09951-00810

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

4. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING INNER RACE

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

SST : 09309-14020





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

5. INSTALL FRONT DIFFERENTIAL CASE BEARING OUTER RACE LH

(a) Remove the differential carrier from the overhaul attachment.

(b) Install the differential case washer to the differential carrier.

HINT
* If the final gear set (drive pinion and ring gear) or differential case bearing are replaced, select and install the thinnest differential case washer first.
* If the drive pinion, ring gear or differential case are reused, select and install a differential case washer with the same thickness as the one before the disassembly first.

(c) Using SST and a press, press in the case bearing outer race to the differential carrier.

SST : 09950-60020

09951-00680

09951-00790

09952-06010

SST : 09950-70010

09951-07100





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

6. INSTALL FRONT DIFFERENTIAL CASE BEARING OUTER RACE RH

(a) Install the differential case washer to the differential carrier retainer.

HINT
* If the final gear set (drive pinion and ring gear) or differential case bearing are replaced, select and install the thinnest differential case washer first.
* If the drive pinion, ring gear or differential case are reused, select and install a differential case washer with the same thickness as the one before the disassembly first.

(b) Using SST and a press, press in the case bearing outer race to the differential carrier retainer.

SST : 09950-60020

09951-00790

09951-00890

09952-06010

SST : 09950-70010

09951-07100





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

7. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR

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

SST : 09612-30012

SST : 09950-70010

09951-07100





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

8. ADJUST DRIVE PINION PRELOAD

(a) Fix the differential carrier with an attachment.

(b) Install the drive pinion to the differential carrier, and then install the bearing inner race and oil slinger while supporting the drive pinion by hand.





NOTICE:
* Do not apply hypoid gear oil to a new bearing.
* Do not drop the drive pinion.

HINT
Install the spacer and oil seal after performing the ring gear tooth contact pattern inspection adjustment.

(c) Using SST, install the companion flange.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020





NOTICE:
* As a bearing spacer is not installed, if SST is tightened excessively, SST, the companion flange, and drive pinion will be damaged.
* Support the drive pinion by hand until SST is installed.
* Be careful not to drop the drive pinion.

HINT
* Before using SST center bolt, apply hypoid gear oil to its threads and tip.
* Install the companion flange so that there is some free play in the drive pinion.

(d) Remove SST.

(e) Using SST and a torque wrench, tighten the flange nut little by little until it reaches the specified preload.

SST : 09213-58013

SST : 09330-00021

SST : 09229-55010





Maximum torque:

490 N*m (4997 kgf*cm, 361 ft.*lbf)

NOTICE:
* Tighten the nut with a force of 100 N*m (1020 kgf*cm. 74 in.*lbf) while checking the starting torque of the drive pinion.
* As the bearing spacer is not installed, tighten the flange nut little by little. Do not overtighten the nut.
* Do not overtighten the nut, as the threads will become damaged.
* Coat the threads the flange nut and drive pinion with hypoid gear oil LSD.
* Perform the installment while supporting the overhaul attachment.

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

SST : 09229-55010





Drive Pinion Preload (at starting):





NOTICE:
For a more accurate measurement, rotate the bearing forward and backward before the inspection.

HINT
Record the preload for total preload measurement.

9. INSTALL DIFFERENTIAL CASE

(a) Remove the differential carrier from the overhaul attachment.

(b) Install the differential case to the differential carrier.





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

10. INSPECT AND ADJUST DIFFERENTIAL RING GEAR BACKLASH

(a) Install the retainer to the differential carrier with the 11 bolts.





Torque : 58 Nm (591 kgf-cm, 43 ft-lbf)

(b) Install the differential carrier to the overhaul attachment.





(c) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.





(d) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.

SST : 09564-50010





Standard backlash:

0.13 to 0.23 mm (0.00512 to 0.00905 in.)

HINT
* Measure at 3 or more areas around the circumference of the ring gear.
* Record the measured value, as it is used to select the differential case washer.
* If the result is outside of the standard range, replace the washer with one of a different thickness in accordance with the following procedure.
* Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential case washer LH and RH.

(e) Select a washer from the table until the backlash measured value is in the standard range.

Washer Thickness (LH):





Washer Thickness (RH):





HINT
* Make sure to increase the thickness of the LH and RH differential case washer by the same amount each time until the backlash is in the standard range.
* Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential case washer LH and RH.
* When adjusting the backlash, adjust to within 0.18 mm (0.00709 in.) of the average of the measurements.

11. INSPECT AND ADJUST TOTAL PRELOAD

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

SST : 09229-55010





Total Preload (at starting):





HINT
* When the value is outside the standard range, adjust using the differential case washer on the ring gear tooth side.
* When the value is less than the lower limit of the standard range, replace the differential case washer with a thicker one.
* When the value is more than the upper limit of the standard range, replace the differential case washer with a thinner one.
* For reassembly purposes, record the measured value.

(b) Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.





(c) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.

SST : 09564-50010





Standard backlash:

0.13 to 0.23 mm (0.00512 to 0.00905 in.)

HINT
* Measure at 3 or more areas around the circumference of the ring gear.
* If the backlash is not in the standard range, increase the LH and RH differential case washer by the same amount until the backlash is in the standard range.
* Record the measured value and use it when selecting the differential case washer.
* Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential case washer LH and RH.
* When adjusting the backlash, adjust to within 0.18 mm (0.00709 in.) of the average of the measurements.

(d) Recheck the total preload.

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