FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Lexus >> 2008 >> GS 350 AWD V6-3.5L (2GR-FSE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Differential Carrier >> Service and Repair >> Overhaul >> Front Differential Carrier Assembly >> Disassembly

Disassembly









DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): DISASSEMBLY

1. FIX FRONT DIFFERENTIAL CARRIER ASSEMBLY






(a) Set the differential carrier to an overhaul stand, etc., as shown in the illustration.
2. INSPECT DIFFERENTIAL RING GEAR BACKLASH






(a) 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.






(b) Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.
SST: 09564-32011
Backlash:
0.08 to 0.16 mm (0.0031 to 0.0063 in.)
If the backlash is not within the specified range, adjust the ring gear backlash or repair as necessary.
3. INSPECT FRONT DRIVE PINION COMPANION FLANGE FRONT






(a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally.
Maximum runout:
0.1 mm (0.0039 in.)
If the runout is greater than the maximum value, replace the companion flange.
4. INSPECT TOTAL PRELOAD






(a) Using a torque wrench, measure the total preload.
Total preload (at starting):
0.78 to 1.27 N*m (8.0 to 13.0 kgf*cm, 6.9 to 11.2 in.*lbf)
If the total preload is not within the specified range, adjust the total preload or repair as necessary.
5. REMOVE FRONT DIFFERENTIAL BREATHER PLUG






(a) Remove the differential breather plug from the differential carrier.
6. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL






(a) Using SST, remove the 2 oil seals from the differential carrier.
SST: 09308-00010
7. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT






(a) Using SST and a hammer, unstake the staked part of the drive pinion nut.
SST: 09930-00010
NOTICE:

- Be sure to use the 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
SST: 09950-30012
09955-03030
NOTICE:
Apply grease to the threads and tip of the SST center bolt before use.

8. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT






(a) Using SST, remove the companion flange.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
09956-03020
NOTICE:
Apply grease to the threads and tip of the SST center bolt before use.

9. REMOVE FRONT 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
09951-00430
10. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL






(a) Using SST, remove the oil seal from the differential carrier.
SST: 09308-10010
NOTICE:
Apply grease to the threads and tip of the SST center bolt before use.

11. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Remove the drive pinion oil slinger.
12. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING






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

13. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER






(a) Remove the drive pinion bearing spacer.
14. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER






(a) Remove the 8 bolts.






(b) Using a brass bar and hammer, lightly tap the rib of the side bearing retainer to remove it.
(c) Using a scraper and wire brush, clean the seal packing on the differential carrier sub-assembly and side bearing retainer.
(d) Completely remove the oil with cleaning solvent.
15. REMOVE FRONT DIFFERENTIAL CASE
(a) Remove the differential case from the differential carrier.
16. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR






(a) Remove the bolt and differential side bearing retainer deflector.
17. REMOVE DIFFERENTIAL DRIVE PINION
18. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING






(a) Using SST and a press, remove the inner race of the front drive pinion front tapered roller bearing from the drive pinion.
SST: 09950-00020
HINT:
If either the drive pinion or the ring gear is damaged, replace both as a set.

19. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING






(a) Using a brass bar and hammer, remove the outer race of the front drive pinion front tapered roller bearing and front adjust shim from the differential carrier assembly.
HINT:
Set the brass bar onto the concave portion of the differential carrier assembly. Lightly and uniformly tap the bearing and shim to remove them.

20. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING






(a) Using SST, remove the outer race of the front drive pinion rear tapered roller bearing from the differential carrier.
SST: 09502-12010
SST: 09612-65014
09612-01020
09612-01050
NOTICE:

- Insert the SST into the outer race of the front drive pinion rear tapered roller bearing from the concave portion of the differential carrier assembly and engage the claws.
- Apply grease to the threads and tip of the SST center bolt before use.


21. REMOVE FRONT DIFFERENTIAL CASE BEARING






(a) Using SST and a press, remove the LH outer race of the front differential case bearing and case plate washer from the differential carrier.
SST: 09950-60010
09951-00540
SST: 09950-70010
09951-07150
NOTICE:
Put identification marks on the case bearing outer race to distinguish between the RH side and LH side.

22. REMOVE FRONT DIFFERENTIAL CASE BEARING






(a) Using SST and a press, remove the RH outer race of the front differential case bearing and case plate washer from the differential side bearing retainer.
SST: 09950-60010
09951-00540
SST: 09950-70010
09951-07150
NOTICE:
Put identification marks on the case bearing outer race to distinguish between the RH side and LH side.

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 screwdriver and a hammer, unstake the 4 lock plates.






(d) Remove the 8 ring gear set bolts and 4 lock plates.
(e) Using a plastic hammer, tap on the ring gear to separate it from the differential case.
24. REMOVE FRONT 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: 09950-60010
09951-00390
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04061
09957-04010
09958-04011
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.

25. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN






(a) Using a pin punch (3 mm) and hammer, remove the straight pin.






(b) Remove the 2 differential pinions. [A]
(c) Remove the 2 differential pinion thrust washers. [B]
(d) Remove the differential pinion shaft. [C]
(e) Remove the 2 side gears. [D]
(f) Remove the 2 side gear thrust washers No.1. [E]
26. INSPECT DIFFERENTIAL PINION AND SIDE GEAR
(a) Check that there is no damage to the differential pinion gear and side gear. If the differential pinion gear and/or side gear is damaged, replace them with new ones.
27. INSPECT DIFFERENTIAL CASE
(a) Check that there is no damage to the differential case. If the differential case is damaged, replace it.
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