Rear Differential Carrier Assembly: Inspection

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.

INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
1. Set the dial indicator perpendicular to the end of the ring gear face
2. Rotate the ring gear and measure the backlash
  Maximum runout:
  
  0.04 mm (0.00157 in.)
  
  If the runout exceeds the specified maximum value, remove the ring gear and check the runout of the differential case.
  
  Fig 1: Inspecting Runout Of Differential Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIFFERENTIAL RING GEAR BACKLASH
1. While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash
  Backlash:
  
  0.08 to 0.13 mm (0.00315 to 0.00512 in.)
  
  If the backlash is not within the specified range, adjust the backlash or repair as necessary
  
  Fig 2: Inspecting Differential Ring Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

Coat 3 or 4 teeth at the 3 different positions on the ring gear with Prussian blue
Rotate the ring gear in both directions
Inspect the tooth contact pattern

Fig 3: Coating Teeth Different Positions On Ring Gear With Prussian Blue
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 4: Identifying Tooth Contact Pattern
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the teeth are not contacting properly, use the following table to select a proper plate washer for correction

HINT

If the contact pattern is face contact or flank contact, tooth contact may be adjustable while keeping the backlash within the specified range.
If the thickness of the drive pinion washer has been changed, adjust the backlash and measure the total preload

Fig 5: Identifying Plate Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Washer Thickness

WASHER THICKNESS SPECIFICATION

Thickness mm (in.)	No.	Thickness mm (in.)	No.	Thickness mm (in.)	No.
1 87 (0 0736)	87	2 01 (0 0791)	01	2 15 (0 0846)	15
1 88 (0 0740)	88	2 02 (0 0795)	02	2 16 (0 0850)	16
1 89 (0 0744)	89	2 03 (0 0799)	03	2 17 (0 0854)	17
1 90 (0 0748)	90	2 04 (0 0803)	04	2 18 (0 0858)	18
1 91 (0 0752)	91	2 05 (0 0807)	05	2 19 (0 0862)	19
1 92 (0 0756)	92	2 06 (0 0811)	06	2 20 (0 0866)	20
1 93 (0 0760)	93	2 07 (0 0815)	07	2 21 (0 0870)	21
1 94 (0 0764)	94	2 08 (0 0819)	08	2 22 (0 0874)	22
1 95 (0 0768)	95	2 09 (0 0823)	09	2 23 (0 0878)	23
1 96 (0 0772)	96	2 10 (0 0827)	10	2 24 (0 0882)	24
1 97 (0 0776)	97	2 11 (0 0831)	11	2 25 (0 0886)	25
1 98 (0 0780)	98	2 12 (0 0835)	12	2 26 (0 0890)	26
1 99 (0 0783)	99	2 13 (0 0839)	13	2 27 (0 0894)	27
2 00 (0 0787)	00	2 14 (0 0843)	14	2 28 (0 0898)	28

INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
1. Place a dial indicator on the tip of the pinion gear tooth at a right angle Hold the side gear in the differential case and check that the backlash is 0 15 mm (0 00591 in.) or less If not, replace the rear differential case sub-assembly with a new one.
  
  Fig 6: Inspecting Differential Side Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
1. Secure the differential case in a vise between aluminum plates
  NOTE: Do not overtighten the vise.
2. Place a dial indicator on the tip of the side gear tooth at a right angle Hold the pinion gear in the differential case and check that the backlash is 0.15 mm (0.00591 in) or less
  If not, replace the rear differential case sub-assembly with a new one
  
  Fig 7: Inspecting Differential Side Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
1. Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.394 in.) away from the end of the shaft
  Maximum runout:
  
  0.08 mm (0.00315 in.)
  
  If the runout is greater than the maximum, replace the drive pinion and ring gear.
  
  Fig 8: Measuring Runout Of Drive Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
1. Using SST and a torque wrench, measure the starting torque of the drive pinion. The backlash between the drive pinion and ring gear should allow enough movement of the drive pinion to allow this measurement to be performed Make sure not to include the preload of the ring gear (differential case) in the measurement of the drive pinion preload.
  
  Fig 9: Measuring Starting Torque Of Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Drive pinion preload (at starting):
  
  New bearing:
  
  1.2 to 1.8 N*m (13 to 18 kgf*cm, 11 to 15 in.*lbf)
  
  Reused bearing:
  
  0.5 to 0.8 N*m (6 to 8 kgf*cm, 5 to 7 in.*lbf)
  
  If the preload is not within the specified range, adjust the rear differential drive pinion preload or repair as necessary.
INSPECT TOTAL PRELOAD
1. Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
  
  Fig 10: Inspecting Total Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Total preload (at starting):
  
  New bearing:
  
  1.8 to 3.6 N*m (19 to 36 kgf*cm, 16 to 31 in.*lbf)
  
  Reused bearing:
  
  1.1 to 2.6 N*m (12 to 26 kgf*cm, 10 to 23 in.*lbf)
INSPECT RUNOUT OF REAR DIFFERENTIAL CASE SUB-ASSEMBLY
HINT.

Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.
1. Install the differential case to the differential carrier.
  NOTE: Do not damage the case bearing.
  
  Fig 11: Identifying Differential Case To Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, install the differential side bearing outer race RH on the ring gear tooth side.
  SST 09608-32010, 09950-70010 (09951-07200)
  
  HINT:
  
  Tap in the differential side bearing outer race RH until half of the side gear shaft snap ring groove of the differential carrier can be seen.
  
  Fig 12: Tapping Differential Side Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install SST to the differential carrier with the 2 bolts.
  SST 09571-50010
4. Tighten the SST bolt (A) until the SST disc lightly touches the differential side bearing outer race RH
  
  Fig 13: Identifying SST To Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST and a hammer, install the differential side bearing outer race LH on the ring gear back surface side.
  
  Fig 14: Tapping Differential Side Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09608-32010, 09950-70010 (09951-07200)
  
  HINT:
  
  Tap in the differential side bearing outer race LH until it touches the case bearing inner race roller.
6. Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.
7. Place a dial indicator on the differential case flange surface at a right angle.
  
  Fig 15: Identifying Side Gear Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using a dial indicator, measure the differential case runout.
  Maximum runout:
  
  0.04 mm (0.00157 in.)
  
  If the runout is greater than the maximum, replace the rear differential case with a new one.
  
  Fig 16: Measuring Differential Case Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surface side.
  
  Fig 17: Identifying Side Gear Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Tighten the SST bolt to push out the ring gear back surface side differential side bearing outer race LH.
  NOTE: Do not drop the differential side bearing outer race LH.
  
  Fig 18: Pushing Differential Side Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Remove the 2 bolts and SST
  
  Fig 19: Identifying SST On Differential
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Raise the ring gear side of the differential case slightly to remove the ring gear tooth side differential side bearing outer race RH.
  
  Fig 20: Removing Differential Side Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Remove the differential case from the differential carrier as shown in the illustration.
  NOTE: Do not damage the case bearing.
  
  Fig 21: Removing Rear Differential Case Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002