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Home >> Lexus >> 2016 >> GS F >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Axle Hubs, Steering Knuckle And Differential - Service Information >> Rear Differential Carrier Assembly >> Installation [10/2015 - ] >> Procedure

Installation [10/2015 - ]: Procedure

  1. INSTALL TEMPERATURE SENSOR (for LH Side) 
    1. Using a 22 mm deep socket wrench, install a new gasket and temperature sensor.
      GTY517505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 39.2 N*m (400 kgf*cm, 29 ft.*lbf) 

  2. INSTALL TEMPERATURE SENSOR (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

  3. INSTALL TORQUE TRANSFER MODULE MOTOR SUB-ASSEMBLY (for LH Side) 
    1. Apply ATF WS to a new O-ring and install the O-ring to the torque transfer module motor sub-assembly.
      GTY510402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      ATF WS
    2. Install the torque transfer module motor sub-assembly with the 2 bolts.
      GTY497557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      NOTE:

      Make sure that the wire harness for the temperature sensor passes through the clearance between the torque transfer module motor sub-assembly and torque transfer module and is not pinched or pulled.

    3. Engage the claw to install the connector.
    4. Connect the connector.
      GTY497556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TORQUE TRANSFER MODULE MOTOR SUB-ASSEMBLY (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

  5. INSTALL REAR DRIVE SHAFT OIL SEAL LH 
    1. Using SST and a hammer, install a new rear drive shaft oil seal LH.
      GTY519257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Drive Shaft Oil Seal LH
      *a Oil Seal Installation Depth
      • SST: 09649-17010 
      • SST: 09950-70010 
        1. 09951-07150

      Oil Seal Installation Depth

      -0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

      NOTE:
      • Make sure to check the identification marks on the rear drive shaft oil seal LH before installation because the part numbers differ between the left and right sides.
      • To ensure a proper seal, evenly tap in the rear drive shaft oil seal LH.
      • When installing the rear drive shaft oil seal LH, tap it in until the outer surface is flush with the torque transfer module.
      • Make sure the difference between the maximum and minimum measured values of the oil seal installation depth is less than 0.58 mm (0.0228 in.), as a greater difference may lead to fluid leaks.
  6. INSTALL REAR DRIVE SHAFT OIL SEAL RH 

    HINT: 

    Use the same procedure as for the LH side.

  7. INSTALL REAR DIFFERENTIAL CARRIER COVER 
    1. Remove any old seal packing from the rear differential carrier and rear differential carrier cover using a scraper and wire brush. Then remove the oil with non-residue solvent or equivalent.
      NOTE:

      Do not damage the contact surface.

    2. Apply seal packing to the rear differential carrier as shown in the illustration.
      GTY521007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing
      *b 2 to 3 mm (0.0787 to 0.118 in.)

      Seal Packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      HINT: 

      • Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
      • Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.).
      • Install the rear differential carrier cover within 3 minutes of applying seal packing. If the rear differential carrier cover is not installed within 3 minutes of applying seal packing, completely remove and then reapply seal packing.
      • After installing the rear differential carrier cover, do not add oil within 1 hour or allow rapid acceleration or deceleration within 12 hours.
    3. Install the rear differential carrier cover with the 8 bolts.
      GTY497564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 46.6 N*m (475 kgf*cm, 34 ft.*lbf) 

  8. INSTALL REAR DIFFERENTIAL BREATHER PLUG 
    1. Install the rear differential breather plug to the rear differential carrier.
      GTY497562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20.6 N*m (210 kgf*cm, 15 ft.*lbf) 

      HINT: 

      Use the same procedure for the other side.

    2. Install the rear differential breather plug to the rear differential carrier cover.
      GTY497563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20.6 N*m (210 kgf*cm, 15 ft.*lbf) 

  9. INSTALL REAR DIFFERENTIAL FILLER PLUG (for Upper Side) 
    1. Using an 8 mm hexagon socket wrench, install 3 new rear differential filler plugs to the torque vectoring differential FDU (Final Drive Unit).

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      NOTE:

      When using a new torque vectoring differential FDU (Final Drive Unit) or rear differential carrier cover, use new rear differential filler plugs.

      GTY496357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL TORQUE VECTORING DIFFERENTIAL FDU (FINAL DRIVE UNIT) 
    NOTE:
    • Do not damage the installation surface when installing the torque vectoring differential FDU (Final Drive Unit).
    • The remaining oil may leak out when installing the torque vectoring differential FDU (Final Drive Unit).
    • Securely support the torque vectoring differential FDU (Final Drive Unit) while performing this step to avoid excessively tilting or dropping the torque vectoring differential FDU (Final Drive Unit).
    • Install the bolts with the torque vectoring differential FDU (Final Drive Unit) secured.
    1. Install the 2 rear upper differential mount stoppers.
      GTY497703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Support the torque vectoring differential FDU (Final Drive Unit) with 4 attachments or equivalent tools as shown in the illustration.
      GTY501697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Attachment
      WARNING:
      GTY658010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • The torque vectoring differential FDU (Final Drive Unit) is a heavy component. Make sure that it is supported securely.
      • If the torque vectoring differential FDU (Final Drive Unit) is not securely supported, it may drop, resulting in serious injury.
      NOTE:

      Use attachments or equivalent tools to keep the torque vectoring differential FDU (Final Drive Unit) level.

    3. Temporarily install the rear suspension member sub-assembly to the torque vectoring differential FDU (Final Drive Unit).
    4. Temporarily install the torque vectoring differential FDU (Final Drive Unit) to the rear suspension member sub-assembly with the 2 rear lower differential mount stoppers and 2 new bolts.
      GTY497704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Install using a bolt with the same shape as the removed bolt

      GTY812924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Type A Bolt Length Beneath Head 97 mm (3.82 in.)
      *b Type B Bolt Length Beneath Head 101 mm (3.98in.)
    5. Using a 12 mm hexagon socket wrench, temporarily install the torque vectoring differential FDU (Final Drive Unit) to the rear suspension member sub-assembly with 3 new bolts.
      GTY497781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Before installing the bolts, make sure that there is no clearance between the torque vectoring differential FDU (Final Drive Unit) and rear differential mount cushion.

    6. Using a 12 mm hexagon socket wrench, tighten the 3 bolts.

      Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

      NOTE:

      Do not tilt the sleeve or deform the rubber of the rear differential mount cushion when tightening the bolt.

      HINT: 

      Tighten the 2 bolts (A) first.

    7. Tighten the 2 bolts.
      GTY497704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Type A Bolt Length Beneath Head 97 mm (3.82 in.) 

      Torque: 95.1 N*m (970 kgf*cm, 70 ft.*lbf) 

      Type B Bolt Length Beneath Head 101 mm (3.98in.) 

      Torque: 88.9 N*m (907 kgf*cm, 66 ft.*lbf) 

  11. INSTALL REAR SUSPENSION ARM BRACKET ASSEMBLY 

    Refer to PROCEDURE - Step 17

  12. INSTALL NO. 4 FLOOR WIRE 
    1. Insert the 4 pins to temporarily install the No. 4 floor wire.
      GTY507406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Connector (A) *b Connector (B)
      *c Lock *d Pin
      *e Clamp - -
    2. Engage the 2 clamps.
    3. Connect the 2 connectors (A).
    4. Connect the 2 connectors (B) as shown in the illustration to connect the No. 4 floor wire.

      HINT: 

      When connecting the connector with lock lever, return the lock lever to its original position to engage the claw and securely push in the lock of the lock lever to connect the connector as shown in the illustration.

    5. Install the 6 bolts.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

  13. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY 

    Refer to INSTALLATION [10/2015 - ]

  14. CONNECT NO. 4 FLOOR WIRE 
    1. Pass the No. 4 floor wire through the grommet hole to the inside of the vehicle.
    2. Install the nut.
      GTY676772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Grommet
      Nut

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    3. Engage the clamp.
    4. Engage the grommet to connect the No. 4 floor wire.
    5. Engage the clamp.
      GTY652301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Connector (A) *b Connector (B)
      *c Lock - -
    6. Connect the 2 connectors (B) as shown in the illustration to connect the No. 4 floor wire.

      HINT: 

      When connecting the connector with lock lever, return the lock lever to its original position to engage the claw and securely push in the lock of the lock lever to connect the connector as shown in the illustration.

    7. Connect the connector (A).
  15. INSTALL ECU BRACKET (w/ Spare Tire) 

    See step  2

  16. INSTALL NO. 1 FLOOR UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 8

  17. INSTALL SPARE TIRE (w/ Spare Tire) 
  18. INSTALL SPARE WHEEL COVER TRAY (w/o Spare Tire) 

    Refer to PROCEDURE - Step 28

  19. INSTALL SPARE WHEEL COVER TRAY (w/ Spare Tire) 

    Refer to PROCEDURE - Step 29

  20. INSTALL LUGGAGE COMPARTMENT TRIM BOX (w/o Spare Tire) 

    Refer to PROCEDURE - Step 30

  21. INSTALL LUGGAGE COMPARTMENT FLOOR MAT (w/o Spare Tire) 

    Refer to PROCEDURE - Step 31

  22. INSTALL LUGGAGE COMPARTMENT FLOOR MAT (w/ Spare Tire) 

    Refer to PROCEDURE - Step 32

  23. ADD DIFFERENTIAL OIL 

    Refer to PROCEDURE - Step 5

  24. ADD TORQUE TRANSFER MODULE FLUID 

    Refer to PROCEDURE - Step 4

  25. INSPECT FOR TORQUE TRANSFER MODULE FLUID AND DIFFERENTIAL OIL LEAK 

    Refer to PROCEDURE - Step 6

  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [10/2015 - 09/2016] , or Refer to INITIALIZATION [09/2016 - 09/2017] , or Refer to INITIALIZATION [09/2017 - ]

  27. TORQUE VECTORING DIFFERENTIAL SYSTEM CALIBRATION 
    1. When the torque transfer module motor sub-assembly is removed/installed, or the torque vectoring differential FDU (Final Drive Unit) is replaced, Learning Value Initialization must be performed.

      Refer to CALIBRATION [10/2015 - ]

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