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Home >> Lexus >> 2006 >> IS 250 RWD, Automatic >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Differential >> FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) >> Disassembly

FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): Disassembly

  1. SECURE FRONT DIFFERENTIAL CARRIER ASSEMBLY 
    1. Set the differential carrier to an overhaul stand, etc., as shown in Fig 1 .
    Fig 1: Securing Front Differential Carrier Assembly
    G04046990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT DIFFERENTIAL RING GEAR BACKLASH (See  INSPECTION   ) 
  3. INSPECT FRONT DRIVE PINION COMPANION FLANGE (See step 2 in  INSPECTION   ) 
  4. INSPECT AND ADJUST DIFFERENTIAL DRIVE PINION PRELOAD (See step 3 in  INSPECTION   ) 
  5. INSPECT TOTAL PRELOAD (See step 4 in  INSPECTION   ) 
  6. REMOVE FRONT DIFFERENTIAL BREATHER PLUG 
    1. Remove the differential breather plug from the differential carrier.
    Fig 2: Identifying Front Differential Breather Plug
    G04046991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FRONT DIFFERENTIAL CASE OIL SEAL 
    1. Using SST, remove the 2 oil seals from the differential carrier.

    SST 09308-00010 

    Fig 3: Removing Oil Seals From Differential Carrier
    G04046992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER 
    1. Remove the 8 bolts.
      Fig 4: Identifying Front Differential Side Bearing Retainer Bolts
      G04046993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and hammer, lightly tap the rib of the side bearing retainer to remove it.
    3. Using a scraper and wire brush, clean the seal packing on the differential carrier sub-assembly and side bearing retainer.
      NOTE: Do not scratch the sealing surface.
    4. Completely remove the oil with cleaning solvent.
    Fig 5: Removing Rib Of Side Bearing By Tapping Using Brass Bar And Hammer
    G04046994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT DIFFERENTIAL CASE 
    1. Remove the differential case from the differential carrier.
    Fig 6: Removing Front Differential Case
    G04046995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See  INSPECTION   ) 
  11. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT 
    1. Using SST and a hammer, unstake the staked part of the drive pinion nut.

      SST 09930-00010 

      NOTE:
      • 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.
      Fig 7: Unstaking Staked Part Of Drive Pinion Nut
      G04046996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST to hold the flange, remove the drive pinion nut.

    SST 09330-00021, 09950-30012 (09955-03030) 

    Fig 8: Removing Drive Pinion Nut
    G04046997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT DRIVE PINION COMPANION FLANGE 
    1. Using SST, remove the companion flange.

    SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) 

    NOTE: Apply grease to the threads and the tip of the SST center bolt before use.
    Fig 9: Removing Front Drive Pinion Companion Flange Using SST
    G04046998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR 

    HINT:

    Perform this procedure only when the dust deflector is damaged.

    1. Using SST and a press, remove the dust deflector.

    SST 09950-00020, 09950-60010 (09951-00430), 09950-70010 (09951-07100) 

    Fig 10: Removing Dust Deflector
    G04046999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL 
    1. Using SST, remove the oil seal from the differential carrier.

    SST 09308-00010 

    Fig 11: Removing Oil Seal From Differential Carrier Using SST
    G04047000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 
    1. Remove the drive pinion oil slinger.
    Fig 12: Removing Drive Pinion Oil Slinger
    G04047001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Using SST, remove the inner race of the front drive pinion rear tapered roller bearing from the drive pinion.

    SST 09556-22010 

    NOTE:
    • Apply grease to the threads and the tip of the SST center bolt before use.
    • Do not drop the drive pinion.
    Fig 13: Removing Front Drive Pinion Rear Tapered Roller Bearing
    G04047002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER 
    1. Remove the drive pinion bearing spacer.
      Fig 14: Removing Front Differential Drive Pinion Bearing Spacer
      G04047003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE DIFFERENTIAL DRIVE PINION 
    1. Remove the differential drive pinion from the differential carrier.
    NOTE: Do not drop the drive pinion.
  19. REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR 
    1. Remove the bolt and differential side bearing retainer deflector.
    Fig 15: Removing Front Differential Side Bearing Retainer Deflector Bolt
    G04047004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. 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 

      NOTE: Do not drop the drive pinion.

      HINT:

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

      Fig 16: Removing Inner Race Of Front Drive Pinion Front Tapered Roller Bearing From Drive Pinion
      G04047005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.
    Fig 17: Removing Outer Race Of Front Drive Pinion Front Tapered Roller Bearing
    G04047006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. 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.

    Fig 18: Removing Outer Race Of Front Drive Pinion Rear Tapered Roller Bearing From Differential Carrier Assembly
    G04047007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FRONT DIFFERENTIAL CASE BEARING 
    1. 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), 09950-70010 (09951-07100) 

    NOTE: 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.

    Fig 19: Removing Front Differential Case Bearing
    G04047008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DIFFERENTIAL CASE BEARING 
    1. 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), 09950-70010 (09951-07150) 

    NOTE: 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.

    Fig 20: Removing Front Differential Case Bearing
    G04047009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE DIFFERENTIAL RING GEAR 
    1. Hold the differential case in a vise between aluminum plates.
      NOTE: Do not overtighten the vise.
    2. Put matchmarks on the ring gear and differential case.
      Fig 21: Identifying Matchmarks On Ring Gear And Differential Case
      G04047010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a chisel and a hammer, unstake the 4 lock plates.
    4. Remove the 8 ring gear set bolts and 4 lock plates.
      Fig 22: Removing Ring Gear Set Bolts & Lock Plates
      G04047011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
      Fig 23: Tapping Ring Gear To Separate
      G04047012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: 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.

    1. Hold the differential case in a vise between aluminum plates.
      NOTE: Do not overtighten the vise.
    2. 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), 09950-60010 (09951-00300, 09951-00390, 09952-06010) 

    NOTE:
    • 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.
    Fig 24: Removing Case Bearing Inner Races LH And RH
    G04047013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE DIFFERENTIAL PINION AND SIDE GEAR 
    1. Using a pin punch (diameter 3 mm) and hammer, remove the straight pin.
      Fig 25: Removing Straight Pin
      G04047014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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]
      Fig 26: Identifying Differential Case Parts
      G04047015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the differential pinion shaft from the differential case.
      Fig 27: Removing Differential Pinion Shaft From Differential Case
      G04047016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 differential pinions and 2 differential pinion thrust washers from the differential case.
      Fig 28: Removing Differential Pinions & Differential Pinion Thrust Washers From Differential Case
      G04047017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 side gears and 2 side gear thrust washers from the differential case.
    Fig 29: Removing Side Gears & Side Gear Thrust Washers From Differential Case
    G04047018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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