Front Differential Carrier Assembly: Disassembly

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.

FIX FRONT DIFFERENTIAL CARRIER ASSEMBLY TO OVERHAUL STAND
1. Set the differential carrier to an overhaul stand as shown in the illustration.
  
  Fig 1: Identifying Differential Carrier On Overhaul Stand
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIFFERENTIAL RING GEAR BACKLASH
1. Set a lever probe to a dial indicator. Insert the probe into the drain plug hole and set it onto the edge of one of the teeth of the ring gear at a right angle.
  
  Fig 2: Inserting Probe Into Drain Plug Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, turn the differential case clockwise and counterclockwise and measure the ring gear backlash while holding the companion flange with your hand.
  SST 09564-50010
  
  Standard backlash:
  
  0.13 to 0.23 mm (0.00512 to 0.00905 in.)
  
  HINT:
  - Measure at 3 or more areas around the circumference of the ring gear
  - For reassembly purposes, record the result before disassembly
  If the backlash is not within the specified range, adjust the ring gear backlash or repair as necessary
  
  Fig 3: Measuring Differential Ring Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY

Fig 4: Measuring Runout Of Front Drive Pinion Companion Flange Front Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Wipe the inside surface of the companion flange with a cloth or equivalent and remove dirt and foreign matter.
2. Perform the vertical runout inspection.
  1. Set a lever probe to a dial indicator and set the probe at a right angle to the inner surface of the companion flange.
  2. Measure the vertical runout of the companion flange
    Maximum runout:
    
    0.12 mm (0.00472 in.)
    
    If the runout is greater than the maximum value, replace the companion flange.
    
    HINT:
    
    For reassembly purposes, record the result before disassembly.
3. Perform the horizontal runout inspection.
  1. Set a dial indicator at a right angle to the surface of the companion flange as shown in the illustration.
  2. Measure the horizontal runout of the companion flange
    Maximum runout:
    
    0.08 mm (0.00314 in.)
    
    If the runout is greater than the maximum value, replace the companion flange
    
    HINT
    
    For reassembly purposes, record the result before disassembly.
REMOVE FRONT DIFFERENTIAL BREATHER PLUG
1. Remove the differential breather plug from the differential carrier
  
  Fig 5: Locating Front Differential Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE OIL SEAL
1. Using SST, remove the oil seal LH from the differential carrier.
  SST 09308-00010
  
  Fig 6: Removing Differential Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the oil seal RH from the differential carrier.
  SST 09308-00010
  
  Fig 7: Removing RH Differential Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CARRIER RETAINER SUB-ASSEMBLY
1. Loosen the 11 bolts.
  
  Fig 8: Locating Differential Carrier Retainer Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the differential carrier from the overhaul attachment
  
  Fig 9: Identifying Differential Carrier On Overhaul Stand
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 11 bolts.
  
  Fig 10: Locating Differential Carrier Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert the blade of an oil pan seal cutter between the differential carrier and differential carrier retainer. Cut through the applied seal packing
  NOTE: Do not damage the installation surface of the differential carrier.
  
  Fig 11: Inserting Blade Of Oil Pan Seal Cutter Between Differential Carrier And Differential Carrier Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a brass bar and hammer, lightly tap the retainer to remove it from the differential carrier.
  
  Fig 12: Removing Retainer From Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 FRONT DIFFERENTIAL CASE SUB-ASSEMBLY
1. Remove the differential case from the differential carrier.
  NOTE: Do not damage the differential case bearing and ring gear.
  
  Fig 13: Identifying Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
1. Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.
  
  Fig 14: Applying Coat Of Prussian Blue On Differential Ring Gear Teeth
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the differential case to the differential carrier.
  
  Fig 15: Identifying Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the retainer with the 11 bolts
  Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf)
  
  Fig 16: Locating Differential Carrier Retainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Rotate the companion flange several times in the forward and backward rotation directions
  
  Fig 17: Rotating Companion Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 11 bolts and retainer
6. Remove the differential case from the differential carrier
7. Inspect the tooth contact pattern.
  HINT:
  
  For reassembly purposes, record the result before disassembly.
  
  Fig 19: Identifying Tooth Contact Pattern
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FIX DIFFERENTIAL CARRIER
1. Fix the differential carrier to the overhaul stand's.
  
  Fig 20: Identifying Differential Carrier On Overhaul Stand
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
1. Remove the 2 bolts and differential breather plug oil deflector.
  
  Fig 21: Locating Front Differential Breather Plug Oil Deflector Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
1. Using SST and a hammer, unstake the staked part of the drive pinion companion flange nut
  SST 09930-00010
  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.
    
    Fig 22: Unstaking Staked Part Of Drive Pinion Companion Flange Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the flange, remove the drive pinion companion flange nut.
  SST 09213-58013, 09229-55010, 09330-00021
  
  NOTE: Perform the removal while supporting the overhaul attachment.
  
  Fig 23: Removing Drive Pinion Companion Flange Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY
1. Using SST, remove the companion flange from the differential carrier
  SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
  
  HINT
  
  Before using SST center bolt, apply hypoid gear oil to its threads and tip
  
  Fig 24: Removing Companion Flange From Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR
1. Using SST and a press, press out the dust deflector from the companion flange.
  SST 09950-00020, 09950-60010 (09951 -00430), 09950-70010 (09951-07100)
  NOTE:
  - Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the dust deflector.
  - Do not drop the companion flange.
    
    Fig 25: Removing Front Differential Dust Deflector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL
1. Using a SST, remove the oil seal from the differential carrier.
  SST 09308-00010
  
  Fig 26: Removing Front Differential Carrier Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
1. Remove the drive pinion oil slinger from the differential carrier.
  
  Fig 27: Identifying Front Differential Drive Pinion Oil Slinger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING INNER RACE
1. Remove the differential carrier together with the overhaul attachment from the engine stand.
  
  Fig 28: Identifying Differential Carrier With Attachment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set the differential carrier to an overhaul stand, etc., as shown in the illustration.
  
  Fig 29: Identifying Differential Carrier Attachment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a press, press out the drive pinion.
  NOTE: Do not drop the drive pinion.
  
  Fig 30: Removing Drive Pinion And Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the bearing inner race from the differential carrier.
  
  Fig 31: Identifying Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the differential carrier to the overhaul attachment as it was installed previously
  
  Fig 32: Identifying Differential Carrier With Attachment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the differential carrier together with overhaul attachment to the engine stand.
  
  Fig 33: Identifying Differential Carrier Attachment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
1. Remove the bearing spacer from the drive pinion.
  
  Fig 34: Identifying Front Differential Drive Pinion Bearing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING INNER RACE
1. Using SST and a press, remove the front tapered roller bearing inner race from the drive pinion.
  SST 09950-00020
  
  NOTE: Do not drop the drive pinion.
  
  HINT.
  
  Perform this procedure while tightening SST nut to secure the contact surfaces of SST and the front tapered roller bearing inner race. If either the drive pinion or the ring gear is damaged, replace both as a set.
  
  Fig 35: Removing Front Drive Pinion Front Tapered Roller Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING OUTER RACE
1. Using SST, remove the bearing outer race from the differential carrier
  SST 09387-00041 (09387-02020)
  
  Fig 36: Removing Front Drive Pinion Rear Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING OUTER RACE
1. Using SST and a hammer, tap out the bearing outer race and adjusting shim from the differential carrier
  SST 09950-70010 (09951 -07150), 09950-60010 (09951-00610, 09951-00650, 09952-06010)
  
  HINT.
  
  For reassembly purposes, measure the thickness of the adjusting shim, and record the result
  
  Fig 37: Removing Front Drive Pinion Front Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE BEARING OUTER RACE LH
1. Using SST and a press, press out the bearing outer race and case washer from the differential carrier
  SST 09950-60010 (09951 -00640, 09952-06010), 09950-60020 (09951-00680), 09950-70010 (09951-07100)
  
  Fig 38: Removing Front Differential Case Bearing Outer Race LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE BEARING OUTER RACE RH
1. Using SST and a press, press out the bearing outer race and case washer from the differential carrier.
  SST 09950-60010 (09951 -00500), 09950-70010 (09951-07100, 09951-00330, 09952-06010)
  
  Fig 39: Removing Front Differential Case Bearing Outer Race RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL RING GEAR
1. Hold the differential case in a vise between aluminum plates.
  NOTE: Do not overtighten the vise. Matchmark.
  
  Fig 40: Identifying Differential Case In Vise Between Aluminum Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Put matchmarks on the ring gear and differential case.
  
  Fig 41: Identifying Matchmarks On Ring Gear And Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 10 ring gear set bolts.
4. Remove the differential case from the vise.
5. Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.
  HINT:
  
  Place a cloth on the tooth side of the ring gear to prevent damage
  
  Fig 43: Removing Ring Gear From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002