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Home >> Lexus Truck >> 2012 >> RX 350 AWD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Differential Carrier >> Service and Repair >> Overhaul >> Reassembly >> Part 2

Part 2





AXLE AND DIFFERENTIAL: REAR DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY

20. INSTALL DIFFERENTIAL DRIVE PINION

(a) Install the differential drive pinion to the differential carrier.





21. TEMPORARILY TIGHTEN REAR DRIVE PINION NUT

(a) Apply hypoid gear oil LSD to the threads of the rear drive pinion nut and its seating surface.

(b) Using SST, temporarily install the rear drive pinion nut to the differential drive pinion.





SST : 09556-16011

SST : 09564-16020

(c) Using SST and a torque wrench, inspect the differential drive pinion preload (starting torque).





SST : 09556-16011

Standard Differential Drive Pinion Preload (Starting Torque)





HINT
For a more accurate measurement, rotate the bearing forward and backward before adjustment.

(d) If the preload is insufficient, use SST to tighten the differential drive pinion nut 5 to 10° at a time. Measure the preload and repeat the adjustment as necessary until the preload matches the specified torque.





SST : 09556-16011

SST : 09564-16020

without SST - Torque : 321 Nm (3273 kgf-cm, 237 ft-lbf) or less

with SST - Torque : 301 Nm (3069 kgf-cm, 222 ft-lbf) or less

HINT
Use a torque wrench with a fulcrum length of 750 mm (2.46 ft.).

(e) If the tightening torque of the rear drive pinion nut exceeds the specified torque but the preload is still insufficient, remove the rear drive pinion nut. Then check if the rear drive pinion nut and differential drive pinion screw threads are damaged.

(f) If there is no defect, replace the rear differential drive pinion bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.

22. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

(a) Install the rear differential breather plug oil deflector with the 2 bolts.





Torque : 6.5 Nm (66 kgf-cm, 58 in-lbf)

23. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY

(a) Install the rear differential case assembly to the rear differential carrier.





24. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

(a) Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.





Torque : 42 Nm (430 kgf-cm, 31 ft-lbf)

25. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a differential ring gear tooth tip.





(b) Using SST, hold the differential drive pinion in place.

SST : 09556-16011

(c) Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

SST : 09564-32011

Backlash:

0.13 to 0.25 mm (0.00512 to 0.00984 in.)

If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

HINT
Measure at 3 or more areas on the circumference of the differential ring gear.

26. MEASURE TOTAL PRELOAD

(a) Using SST and a torque wrench, measure the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.





SST : 09556-16011

Standard Total Preload (Starting Torque)





HINT
For a more accurate measurement, rotate the rear differential case bearing forward and backward before measuring.

(b) If the results are not within the specification, perform the procedure below:

(1) Select a thicker or thinner rear differential side gear shaft plate washer for the RH side, and then install the rear differential case bearing outer race (RH side only).

(2) Repeat the total preload measurement.

(3) Repeat the differential ring gear backlash inspection.

(4) Repeat the differential ring gear and drive pinion tooth contact pattern inspection.

27. INSTALL DIFFERENTIAL SIDE BEARING RETAINER

(a) Remove the 10 bolts and differential side bearing retainer.

(b) Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier and differential side bearing retainer.

NOTICE:
Do not damage the installation surface.

(c) Apply seal packing to the areas indicated in the illustration of the rear differential carrier.





Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
* Start applying seal packing within range (C).
* Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).
* Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
* If there is an area where seal packing is not applied in a continuous bead, be sure to apply seal packing by overlapping the ends of the bead at least 10 mm (0.394 in.).
* Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (C) in the illustration.
* Install the differential side bearing retainer within 10 minutes after applying seal packing. If the differential side bearing retainer is not installed within 10 minutes after applying seal packing, completely remove and then reapply seal packing.

HINT
The center of the bead

* (A): 2.0 mm (0.0787 in.)
* (B): 3.0 mm (0.118 in.)

(d) Install the differential side bearing retainer to the rear differential carrier with the 10 bolts.





Torque : 42 Nm (430 kgf-cm, 31 ft-lbf)

NOTICE:
After installing the differential side bearing retainer, do not immediately add oil or drive the vehicle for at least 1 hour. In addition, avoid sudden acceleration and deceleration for a minimum of 12 hours.

28. INSPECT TOTAL PRELOAD

(a) Using SST and a torque wrench, inspect the total preload (starting torque) with the teeth of the differential drive pinion and differential ring gear in contact.





SST : 09556-16011

Standard Total Preload (Starting Torque)





HINT
For a more accurate measurement, rotate the rear differential case bearing forward and backward before inspection.

29. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Insert a dial indicator and magnetic base through the rear differential filler plug hole, and set it perpendicular to a differential ring gear tooth tip.





(b) Using SST, hold the differential drive pinion in place.

SST : 09556-16011

(c) Using SST, rotate the rear differential case assembly forward and backward, and measure the backlash.

SST : 09564-32011

Backlash:

0.13 to 0.25 mm (0.00512 to 0.00984 in.)

HINT
Measure at 3 or more areas on the circumference of the differential ring gear.

30. STAKE REAR DRIVE PINION NUT

(a) Using a chisel and a hammer, stake the rear drive pinion nut as shown in the illustration.





31. INSTALL DIAPHRAGM OIL SEAL

(a) Using SST and a press, install a new diaphragm oil seal into the rear differential carrier assembly.





Text in Illustration





SST : 09506-35010

SST : 09554-22010

NOTICE:
* Install the diaphragm oil seal uniformly.
* Press fit the diaphragm oil seal straight.

Distance (A):

0.7 to 1.3 mm (0.0276 to 0.0512 in.)

(b) Apply a light coat of MP grease to the lip of the new diaphragm oil seal.

32. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for LH Side)

(a) Using SST and a press, install a new rear differential side gear shaft oil seal into the differential side bearing retainer.





Text in Illustration





SST : 09223-46011

SST : 09631-32020

NOTICE:
* Install the rear differential side gear shaft oil seal uniformly.
* Press fit the rear differential side gear shaft oil seal straight.

Distance (A):

8.2 to 8.8 mm (0.323 to 0.346 in.)

(b) Apply a light coat of MP grease to the lip of the new rear differential side gear shaft oil seal.

33. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for RH Side)

(a) Using SST and a press, install a new rear differential side gear shaft oil seal into the rear differential carrier.





Text in Illustration





SST : 09223-46011

SST : 09631-32020

NOTICE:
* Install the rear differential side gear shaft oil seal uniformly.
* Press fit the rear differential side gear shaft oil seal straight.

Distance (A):

8.2 to 8.8 mm (0.323 to 0.346 in.)

(b) Apply a light coat of MP grease to the lip of the new rear differential side gear shaft oil seal.

34. INSTALL SPACER

(a) Install the spacer to the rear differential carrier assembly.





Text in Illustration





NOTICE:
Keep the spacer free of oil and foreign matter.

35. INSTALL CONICAL SPRING WASHER

(a) Install the conical spring washer to the rear differential carrier assembly.





Text in Illustration





NOTICE:
* Be sure to install the conical spring washer with the convex side facing the rear of the vehicle.
* Keep the conical spring washer free of oil and foreign matter.

36. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY

(a) Using a scraper and wire brush, remove the seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

NOTICE:
* Do not damage the installation surface.
* Be sure to completely remove all seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.
* Do not allow the removed seal packing to enter the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

(b) Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier assembly and the electro magnetic control coupling sub-assembly.

NOTICE:
Do not damage the installation surface.

(c) Apply seal packing to the areas indicated in the illustration of the rear differential carrier assembly.





Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
* Start applying seal packing within range (A).
* Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).
* Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.
* If there is an area where seal packing is not applied in a continuous bead, be sure to apply seal packing by overlapping the ends of the bead at least 10 mm (0.394 in.).
* Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (A) in the illustration.
* Install the electro magnetic control coupling sub-assembly within 10 minutes after applying seal packing. If the electro magnetic control coupling sub-assembly is not installed within 10 minutes after applying seal packing, completely remove and then reapply seal packing.
* After installing the electro magnetic control coupling sub-assembly, do not immediately add oil or drive the vehicle for at least 1 hour.

HINT
The center of the bead

* (A): 20 mm (0.787 in.)
* (B): 1.0 mm (0.0394 in.)
* (C): 1.4 mm (0.0551 in.)
* (D): 3.0 mm (0.118 in.)
* (E): 2.0 mm (0.0787 in.)

(d) Install the electro magnetic control coupling sub-assembly with the 4 bolts.





Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

NOTICE:
* Do not damage the diaphragm oil seal.
* Do not damage the contact surface of the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

37. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG

(a) Using a socket wrench, service nut and a hammer, install the rear differential carrier cover breather plug to the rear differential carrier.





HINT
* Use a service nut with an inner diameter of 13 mm (0.512 in.) and a socket wrench appropriate for the service nut.
* Tap in the rear differential carrier cover breather plug until it sits flush with the rear differential carrier assembly.

38. INSPECT ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY

(a) Install a dial indicator and magnetic base so that it is perpendicular to the inner side of the electro magnetic control coupling sub-assembly as shown in the illustration.





(b) Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the vertical runout.

SST : 09564-32011

Maximum runout:

0.06 mm (0.00236 in.)

If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

(c) Install a dial indicator and magnetic base perpendicular to the electro magnetic control coupling sub-assembly as shown in the illustration.

(d) Using SST, rotate the electro magnetic control coupling sub-assembly forward and backward, and measure the lateral runout.

SST : 09564-32011

Maximum runout:

0.07 mm (0.00276 in.)

If the runout is greater than the maximum value, replace the electro magnetic control coupling sub-assembly.

39. INSTALL REAR DIFFERENTIAL FILLER PLUG

(a) Install a new gasket with the rear differential filler plug.





Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)

40. INSTALL CONNECTOR BRACKET

(a) Install a new clamp to the connector bracket as shown in the illustration.





(b) Install the 2 connector brackets with the 3 bolts.





Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

41. INSTALL ELECTRO MAGNETIC CONTROL COUPLING WIRE HARNESS

(a) Install a new clamp to the electro magnetic control coupling wire harness as shown in the illustration.





Text in Illustration





NOTICE:
Be sure to install the new clamp so that the identification mark is aligned with the clamp.

Distance (A):

83.5 to 89.5 mm (3.29 to 3.52 in.)

(b) Engage the claw to install the electro magnetic control coupling wire harness connector.





(c) Install the electro magnetic control coupling wire harness to the clamp (A).

(d) Install the clamp (B) to the connector bracket.

NOTICE:
Do not damage the electro magnetic control coupling wire harness.

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