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

REAR DIFFERENTIAL CARRIER ASSEMBLY (for 4GR-FSE): Disassembly

  1. REMOVE REAR DIFFERENTIAL BREATHER PLUG 
    1. Remove the breather plug from the differential carrier cover.
    Fig 1: Removing Breather Plug From Differential Carrier Cover
    G04047080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE REAR DIFFERENTIAL CARRIER COVER 
    1. Remove the 8 bolts from the differential carrier cover.
      2. Fig 2: Identifying Differential Carrier Cover Bolts
      G04047081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and hammer, lightly tap the rib of the side bearing retainer to remove it.
    NOTE: Do not damage the sealing surface of the differential carrier.
    Fig 3: Removing Rib Of Side Bearing Retainer
    G04047082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR BOLT 
    1. Remove the bolt and oil deflector from the differential carrier cover.
    Fig 4: Removing Oil Deflector From Differential Carrier Cover Bolt
    G04047083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. SECURE REAR DIFFERENTIAL CARRIER 
    1. Set the differential carrier to an overhaul stand, etc., as shown in Fig 5 .
    Fig 5: Securing Rear Differential Carrier
    G04047084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR (See  INSPECTION   ) 
  6. INSPECT DIFFERENTIAL RING GEAR BACKLASH (See step 2 in  INSPECTION   ) 
  7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See step 11 in  INSPECTION   ) 
  8. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (for 2WD) (See step 3 in  INSPECTION   ) 
  9. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE (See step 7 in  INSPECTION   ) 
  10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (See step 8 in  INSPECTION   ) 
  11. INSPECT TOTAL PRELOAD (See step 9 in  INSPECTION   ) 
  12. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL 
    1. Using SST, remove the 2 oil seals.

    SST 09308-00010 

    Fig 6: Removing Rear Differential Side Gear Shaft Oil Seal
    G04047085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE REAR DRIVE PINION NUT 
    1. Using SST and a hammer, unstake the staked part of the drive pinion nut.

      SST 09930-00010 

      NOTE:
      • Be sure to use 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
      G04047086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST to hold the flange, remove the drive pinion nut.

    SST 09330-00021 

    Fig 8: Removing Drive Pinion Nut
    G04047087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 2WD) 
    1. Using SST, remove the companion flange.

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

    NOTE: Apply grease to the threads and tip of the SST center bolt before use.
    Fig 9: Removing Rear Drive Pinion Companion Flange (For 2WD)
    G04047088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR DRIVE PINION COMPANION FLANGE (for 4WD) 
    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 tip of the SST center bolt before use.
    Fig 10: Removing Rear Drive Pinion companion Flange (For 4WD)
    G04047089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR 

    HINT:

    Perform this procedure only when the dust deflector is damaged.

    1. Using SST and a press, remove the dust deflector.
    Fig 11: Removing Dust Deflector
    G04047090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09950-00020, 09950-60010 (09951-00380), 09950-70010 (09951-07100) 

    NOTE: Do not drop the companion flange.
  17. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL 
    1. Using SST, remove the oil seal from the differential carrier.

    SST 09308-00010 

    Fig 12: Removing Oil Seal From Differential Carrier
    G04047091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 
    1. Remove the drive pinion oil slinger.
    Fig 13: Identifying Drive Pinion Oil Slinger
    G04047092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Using SST, remove the inner race of the rear drive pinion front tapered roller bearing from the drive pinion.

    SST 09556-22010 

    NOTE: Apply grease to the threads and tip of the SST center bolt before use.
    Fig 14: Removing Inner Race Of Rear Drive Pinion Front Tapered Roller Bearing From Drive Pinion
    G04047093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER 
    1. Remove the drive pinion bearing spacer.
    Fig 15: Identifying Drive Pinion Bearing Spacer
    G04047094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    1. Put matchmarks on either set of the bearing cap and differential carrier.
      Fig 16: Identifying Matchmarks Of Bearing Cap And Differential Carrier
      G04047095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and 2 bearing caps.
      NOTE: Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.
    3. Using SST and a hammer, remove the 2 side gear shaft plate washers.

      SST 09504-22011 

      NOTE: Put identification marks on the side gear shaft plate washer to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

      HINT:

      Measure the thickness of the plate washers and note it.

      Fig 17: Removing Side Gear Shaft Plate Washers
      G04047096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the differential case assembly and the case bearing outer races LH and RH from the differential carrier.
    NOTE:
    • Do not damage the differential case bearing or ring gear.
    • Put identification marks on the case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.
    Fig 18: Identifying Differential Case Assembly And Case Bearing Outer Races LH And RH
    G04047097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Remove the drive pinion from the differential carrier.
    2. Using SST and a press, remove the inner race of the rear drive pinion rear tapered roller bearing from the drive pinion.

      SST 09950-00020 

      NOTE: Do not drop the drive pinion.

      HINT:

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

      Fig 19: Removing Inner Race Of Rear Drive Pinion Rear Tapered Roller Bearing From Drive Pinion
      G04047098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the drive pinion plate washer from the drive pinion.

      HINT:

      Measure the thickness of the plate washer and note it.

    4. Using a brass bar and a hammer, remove the outer race of the rear drive pinion front tapered roller bearing from the differential carrier.
    NOTE: Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.
    Fig 20: Removing Rear Drive Pinion Rear Tapered Roller Bearing
    G04047099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Using a brass bar and a hammer, remove the outer race of the rear drive pinion rear tapered roller bearing from the differential carrier.
    NOTE: Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.
    Fig 21: Removing Rear Drive Pinion Rear Front Tapered Roller Bearing
    G04047100Courtesy 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.
    3. Using a chisel and a hammer, unstake the 5 lock plates.
      Fig 22: Identifying Differential Ring Gear
      G04047101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 10 ring gear set bolts and 5 lock plates.
      Fig 23: Identifying Ring Gear Seat Bolts
      G04047102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a plastic hammer, tap on the ring gear to separate it from the differential case.

    HINT:

    Use cloth to prevent damage to the ring gear teeth.

    Fig 24: Tapping Ring Gear To Separate
    G04047103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY (See step 10 in  INSPECTION   ) 
  26. REMOVE REAR DIFFERENTIAL CASE BEARING (for 2WD) 

    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 (09951-00480, 09951-00350, 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 tip of the SST center bolt before use.
    Fig 25: Removing Rear Differential Case Bearing (For 2WD)
    G04047104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE REAR DIFFERENTIAL CASE BEARING (for 4WD) 

    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 (09951-00480, 09951-00330, 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 tip of the SST center bolt before use.
    Fig 26: Removing Rear Differential Case Bearing (For 4WD)
    G04047105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE DIFFERENTIAL PINION AND SIDE GEAR (for 4WD) 
    1. Hold the differential case in a vise between aluminum plates.
      NOTE: Do not overtighten the vise.
    2. Using a pin punch (3 mm) and a hammer, remove the straight pin.
      Fig 27: Removing Straight Pin
      G04047106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the following parts from the differential case.

      HINT:

      • Differential pinion shaft: [A]
      • Differential pinion: [B]
      • Differential pinion thrust washer: [C]
      • Differential side gear: [D]
      • Differential side gear thrust washer: [E]
      Fig 28: Identifying Differential Case Parts
      G04047107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the differential pinion shaft from the differential case.
      Fig 29: Removing Differential Pinion Shaft From Differential Case
      G04047108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 differential pinion gears and 2 differential pinion thrust washers from the differential case.
      Fig 30: Removing Differential Pinion Gears & Differential Pinion Thrust Washers
      G04047109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 differential side gear and 2 differential side gear thrust washers from the differential case.
    Fig 31: Removing Differential Side Gear And Differential Side Gear Thrust Washers
    G04047110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSPECT DIFFERENTIAL PINION AND SIDE GEAR (for 4WD) (See step 12 in  INSPECTION   ) 
  30. INSPECT DIFFERENTIAL CASE ASSEMBLY (for 4WD) (See step 13 in  INSPECTION   ) 
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