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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 >> Front Differential Carrier Assembly >> Disassembly

Disassembly





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

1. SECURE 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 Front Differential Carrier Assembly

3. INSPECT FRONT DRIVE PINION COMPANION FLANGE Front Differential Carrier Assembly

4. INSPECT AND ADJUST DIFFERENTIAL DRIVE PINION PRELOAD Front Differential Carrier Assembly

5. INSPECT TOTAL PRELOAD Front Differential Carrier Assembly

6. REMOVE FRONT DIFFERENTIAL BREATHER PLUG

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





7. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL

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





SST : 09308-00010

8. 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.

NOTICE:
Do not scratch the sealing surface.

(d) Completely remove the oil with cleaning solvent.

9. REMOVE FRONT DIFFERENTIAL CASE

(a) Remove the differential case from the differential carrier.





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

11. REMOVE FRONT DRIVE PINION COMPANION FLANGE 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

12. REMOVE FRONT DRIVE PINION COMPANION FLANGE

(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 the tip of the SST center bolt before use.

13. 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

SST : 09950-70010

09951-07100

14. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

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





SST : 09308-00010

15. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Remove the drive pinion oil slinger.





16. 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 the tip of the SST center bolt before use.
* Do not drop the drive pinion.

17. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Remove the drive pinion bearing spacer.





18. REMOVE DIFFERENTIAL DRIVE PINION

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

NOTICE:
Do not drop the drive pinion.

19. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR

(a) Remove the bolt and differential side bearing retainer deflector.





20. 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

NOTICE:
Do not drop the drive pinion.

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

(b) 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 into the concave portions of the differential carrier assembly. Lightly and uniformly tap the bearing race and shim to remove them.
* For reassembly purposes, measure the thickness of the adjust shim. Write down the result.

21. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using a brass bar and hammer, remove the outer race of the front drive pinion rear tapered roller bearing 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 race to remove it.

22. 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

09951-00550

09952-06010

SST : 09950-70010

09951-07100

NOTICE:
Put identification marks on the case bearing outer race to distinguish between the RH side and LH side.

HINT
For reassembly purposes, measure the thickness of the plate washer. Write down the result.

23. 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.

HINT
For reassembly purposes, measure the thickness of the plate washer. Write down the result.

24. 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 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.





NOTICE:
Do not damage the ring gear.

25. 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 : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04061

09957-04010

09958-04011

SST : 09950-60010

09951-00300

09951-00390

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 the tip of the SST center bolt before use.

26. REMOVE DIFFERENTIAL PINION AND SIDE GEAR

(a) Using a pin punch (dia3 mm) and hammer, remove the straight pin.





(b) Remove the following parts from the differential case.





HINT
* Differential pinion: [A]
* Differential pinion thrust washer: [B]
* Differential pinion shaft: [C]
* Differential side gear: [D]
* Differential side gear thrust washer: [E]

(c) Remove the differential pinion shaft from the differential case.





(d) Remove the 2 differential pinions and 2 differential pinion thrust washers from the differential case.





(e) Remove the 2 side gears and 2 side gear thrust washers from the differential case.




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