Rear Differential Carrier Assembly: Disassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE REAR DIFFERENTIAL BREATHER PLUG
1. Remove the breather plug from the differential carrier cover
  
  Fig 1: Locating Breather Plug From Differential Carrier Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CARRIER COVER
1. Remove the 8 bolts from the differential carrier cover
  
  Fig 2: Locating Differential Carrier Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, remove the differential carrier cover from the differential carrier
  NOTE:
  - Place the brass bar onto the corners of the carrier cover.
  - Do not damage the sealing surface of the differential carrier.
REMOVE REAR DIFFERENTIAL CARRIER STRAIGHT PIN
1. Remove the 2 rear differential carrier straight pins
  
  Fig 3: Tapping Differential Carrier Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
1. Remove the bolt and oil deflector from the differential carrier cover
  
  Fig 4: Locating Oil Deflector Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SECURE REAR DIFFERENTIAL CARRIER
1. Set the differential carrier to the overhaul stand, etc., as shown in the illustration
  
  Fig 5: Setting Differential Carrier To Overhaul Stand
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RUNOUT OF DIFFERENTIAL RING GEAR (See INSPECTION )
INSPECT DIFFERENTIAL RING GEAR BACKLASH (See INSPECTION )
INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See INSPECTION )
INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (See INSPECTION )
INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION (See INSPECTION )
INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (See INSPECTION )
INSPECT TOTAL PRELOAD (See INSPECTION )
REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
1. Using SST, remove the 2 rear differential side gear shaft oil seals
  SST 09308-00010
  
  Fig 6: Removing Rear Differential Side Gear Shaft Oil Seals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for RH Side)
1. Install SST to the differential carrier
  SST 09571-50010
2. Tighten the SST bolt (A) until the SST disc lightly touches the differential side bearing outer race RH
  
  Fig 7: Identifying SST To Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a dial indicator to the rear differential carrier
4. Tighten the SST bolt and alter the shape of the differential carrier to create a 0 1 mm (0 00394 in) clearance between the differential side bearing outer race RH and side gear shaft snap ring
  NOTE: Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.00787 in.).
  
  Fig 8: Tightening SST Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT
  - Set the dial indicator to the rearmost position (upper side in the illustration) of the area around where the side gear shaft oil seal is tapped in.
  - Approximately 0 1 mm (0.00394 in) clearance between the differential side bearing outer race RH and the side gear shaft snap ring is sufficient for the washer to move slightly
5. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.
  HINT:
  
  For reassembly purposes, measure the thickness of the side gear shaft snap ring. Write down the result.
6. Remove the dial indicator and loosen the SST bolt
  NOTE: Do not remove SST.
  
  Fig 9: Identifying Side Gear Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SNAP RING (for LH Side)
1. Using SST and a hammer, create a clearance between the differential side bearing outer race LH on the back surface of the ring gear and side gear shaft snap ring
  SST 09608-32010, 09950-70010 (09951-07200)
  
  HINT
  
  The clearance is not visible, but tapping SST with a hammer three or four times should be enough.
  
  Fig 10: Tapping SST With Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using snap ring pliers, remove the side gear shaft snap ring on the back surface of the ring gear.
  HINT.
  
  For reassembly purposes, measure the thickness of the side gear shaft snap ring Write down the result
  
  Fig 11: Identifying Side Gear Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH
1. Tighten the SST bolt and push out the differential side bearing outer race LH on the back surface of the ring gear.
  SST 09571-50010
  
  NOTE: Do not drop the differential side bearing outer race LH.
  
  Fig 12: Pushing Out Differential Side Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove SST.
  
  Fig 13: Identifying SST On Differential
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH
1. Raise the ring gear of the differential case slightly to remove the ring gear tooth side differential side bearing outer race RH.
  HINT
  
  For reassembly, check the installation position of the differential side bearing outer race and the side gear shaft snap ring before removing the differential side bearing outer race Write down the result.
  
  Fig 14: Removing Differential Side Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
1. Remove the rear differential case sub-assembly.
  NOTE: Do not damage the case bearing.
  
  Fig 15: Removing Rear Differential Case Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION NUT
1. Using SST and a hammer, unstake the staked part of the drive pinion nut.
  SST 09930-00010
  
  Fig 16: Tapping Rear Drive Pinion Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be sure to use SST with the tapered surface facing the shaft.
  - Do not grind the tip of 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.
2. Using SST to hold the flange, remove the drive pinion nut.
  SST 09229-55010, 09330-00021, 09950-30012 (09955-03040)
  
  Fig 17: Holding Flange Removing Drive Pinion Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION COMPANION FLANGE
1. Using SST, remove the companion flange.
  SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03040, 09956-03060)
  
  NOTE: Apply grease to the threads and tip of the SST center bolt before use.
Fig 18: Removing Companion Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  SST 09950-60010 (09951-00440), 09950-00020, 09950-70010 (09951-07100)
Fig 19: Pressing Dust Deflector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL (See REPLACEMENT )
REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
1. Remove the drive pinion oil stinger.
  
  Fig 20: Identifying Drive Pinion Oil Stinger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL DRIVE PINION
1. Using a press, remove the drive pinion from the differential carrier
  NOTE: Do not drop the drive pinion.
  
  Fig 21: Pressing Drive Pinion From Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
1. Remove the rear differential drive pinion bearing spacer from the differential drive pinion.
  
  Fig 22: Identifying Rear Differential Drive Pinion Bearing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Remove the rear drive pinion front tapered roller bearing inner race from the differential carrier.
  
  Fig 23: Identifying Rear Drive Pinion Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, remove the rear drive pinion front tapered roller bearing outer race from the differential carrier
  
  Fig 24: Identifying Rear Drive Pinion Front Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 25: Pressing Rear Drive Pinion Rear Tapered Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
1. Using SST and a press, remove the rear drive pinion rear tapered roller bearing inner race from the drive pinion.
  SST 09950-00020
  
  HINT
  
  If either the drive pinion or ring gear is damaged, replace both as a set
2. Using a brass bar and a hammer, remove the rear drive pinion rear tapered roller bearing outer race from the differential carrier
3. Remove the plate washer.
  
  Fig 26: Removing Rear Drive Pinion Rear Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL RING GEAR
1. Put matchmarks on the ring gear and differential case
2. Remove the 10 ring gear set bolts
  
  Fig 27: Locating Differential Ring Gear Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer, tap on the ring gear to separate it from the differential case
  NOTE: Do not damage the ring gear.
  
  Fig 28: Tapping Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY (See INSPECTION )
REMOVE REAR DIFFERENTIAL CASE BEARING
HINT.

Perform this procedure only when replacing the case bearing or differential case
1. 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 (09951-00350, 09951-00480, 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 29: Removing Case Bearing Inner Races
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIFFERENTIAL SIDE GEAR BACKLASH (See INSPECTION )