Lexus IS250 · Service Manual DRIVE LINE

DISASSEMBLY

Removal / installation


1. REMOVE REAR DIFFERENTIAL BREATHER PLUG

  1. C120859E01
    Remove the breather plug from the differential carrier cover.


2. REMOVE REAR DIFFERENTIAL CARRIER COVER

  1. C120860
    Remove the 8 bolts from the differential carrier cover.

  1. C120861
    Using a brass bar and hammer, lightly tap the rib of the side bearing retainer to remove it.

    NOTICE:
    Do not damage the sealing surface of the differential carrier.


3. REMOVE REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR

  1. C112933
    Remove the bolt and oil deflector from the differential carrier cover.


4. SECURE REAR DIFFERENTIAL CARRIER

  1. C120862
    Set the differential carrier to an overhaul stand, etc., as shown in the illustration.


5. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

  1. C120863
    Using a dial indicator, measure the runout of the ring gear.

    Maximum runout:
    0.07 mm (0.0028 in.)

    If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case.


6. INSPECT DIFFERENTIAL RING GEAR BACKLASH

  1. C120864
    Set the dial indicator perpendicular to the end of the ring gear face.

  1. While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

    Backlash:
    0.13 to 0.18 mm (0.0051 to 0.0071 in.)

    HINT:
    1. Record the measured backlash to use as a reference for selecting a side gear shaft plate washer.
    2. Inspect tooth contact to use the result as a reference for selecting a side gear shaft plate washer.

  1. C120891
    Select a side gear shaft plate washer that will set ring gear backlash within the specified range, and install it to the ring gear back side.
    Washer thickness 
    Thickness mm (in.)
    		 Thickness mm (in.)
    		 Thickness mm (in.)
    2.57 to 2.59 (0.1012 to 0.1020)
    		 2.89 to 2.91 (0.1138 to 0.1146)
    		 3.21 to 3.23 (0.1264 to 0.1271)
    2.59 to 2.61 (0.1020 to 0.1028)
    		 2.91 to 2.93 (0.1146 to 0.1154)
    		 3.23 to 3.25 (0.1271 to 0.1280)
    2.61 to 2.63 (0.1028 to 0.1035)
    		 2.93 to 2.95 (0.1154 to 0.1161)
    		 3.25 to 3.27 (0.1280 to 0.1287)
    2.63 to 2.65 (0.1035 to 0.1043)
    		 2.95 to 2.97 (0.1161 to 0.1169)
    		 3.27 to 3.29 (0.1287 to 0.1295)
    2.65 to 2.67 (0.1043 to 0.1051)
    		 2.97 to 2.99 (0.1169 to 0.1177)
    		 3.29 to 3.31 (0.1295 to 0.1303)
    2.67 to 2.69 (0.1051 to 0.1059)
    		 2.99 to 3.01 (0.1177 to 0.1185)
    		 3.31 to 3.33 (0.1303 to 0.1311)
    2.69 to 2.71 (0.1059 to 0.1067)
    		 3.01 to 3.03 (0.1185 to 0.1193)
    		 3.33 to 3.35 (0.1311 to 0.1319)
    2.71 to 2.73 (0.1067 to 0.1075)
    		 3.03 to 3.05 (0.1193 to 0.1201)
    		 3.35 to 3.37 (0.1319 to 0.1327)
    2.73 to 2.75 (0.1075 to 0.1083)
    		 3.05 to 3.07 (0.1201 to 0.1209)
    		 3.37 to 3.39 (0.1327 to 0.1335)
    2.75 to 2.77 (0.1083 to 0.1091)
    		 3.07 to 3.09 (0.1209 to 0.1217)
    		 3.39 to 3.41 (0.1335 to 0.1343)
    2.77 to 2.79 (0.1091 to 0.1098)
    		 3.09 to 3.11 (0.1217 to 0.1224)
    		 3.41 to 3.43 (0.1343 to 0.1350)
    2.79 to 2.81 (0.1098 to 0.1106)
    		 3.11 to 3.13 (0.1224 to 0.1232)
    		 3.43 to 3.45 (0.1350 to 0.1358)
    2.81 to 2.83 (0.1106 to 0.1114)
    		 3.13 to 3.15 (0.1232 to 0.1240)
    		 3.45 to 3.47 (0.1358 to 0.1366)
    2.83 to 2.85 (0.1114 to 0.1122)
    		 3.15 to 3.17 (0.1240 to 0.1248)
    		 3.47 to 3.49 (0.1366 to 0.1374)
    2.85 to 2.87 (0.1122 to 0.1130)
    		 3.17 to 3.19 (0.1248 to 0.1256)
    		 -
    2.87 to 2.89 (0.1130 to 0.1138)
    		 3.19 to 3.21 (0.1256 to 0.1264)
    		 -

  1. C123416
    Make the differential case bearing and side gear shaft plate washer snug by tapping on the ring gear with a plastic hammer.

  1. C120864
    Set the dial indicator perpendicular to the end of the ring gear face.

  1. While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.

    Backlash:
    0.13 to 0.18 mm (0.0051 to 0.0071 in.)

  1. C120891
    If the backlash is not within the specified range, select a side gear shaft plate washer that will set the ring gear backlash within the specified range and install it into the ring gear back side.

  1. C120983E01
    Select a thicker side gear shaft plate washer so that the clearance between the case bearing outer race end on the ring gear teeth side and the carrier becomes zero or close to zero.

  1. C123416
    Make the differential case bearing and side gear shaft plate washer snug by tapping on the ring gear with a plastic hammer.

  1. C120864
    Set the dial indicator perpendicular to the end of the ring gear face.

  1. While holding the rear drive pinion companion flange, rotate the ring gear and measure the backlash.

    Backlash:
    0.13 to 0.18 mm (0.0051 to 0.0071 in.)

    If the backlash is not within the specified range, adjust the thickness of the right and left side gear shaft plate washers by an equal amount so that the backlash comes within the specified range.


7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

  1. C120911
    Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.

  1. Rotate the ring gear in both directions.

  1. Inspect the tooth contact pattern.

    C120235E01

  1. SA01586E01
    If the teeth are not contacting properly, use the following table to select a proper washer for correction.

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

    Washer thickness: 
    Thickness mm (in.)
    		 Thickness mm (in.)
    		 Thickness mm (in.)
    1.69 to 1.71 (0.0665 to 0.0673)
    		 1.93 to 1.95 (0.0760 to 0.0768)
    		 2.17 to 2.19 (0.0854 to 0.0862)
    1.72 to 1.74 (0.0677 to 0.0685)
    		 1.96 to 1.98 (0.0772 to 0.0780)
    		 2.20 to 2.22 (0.0866 to 0.0874)
    1.75 to 1.77 (0.0688 to 0.0697)
    		 1.99 to 2.01 (0.0783 to 0.0791)
    		 2.23 to 2.25 (0.0878 to 0.0886)
    1.78 to 1.80 (0.0701 to 0.0709)
    		 2.02 to 2.04 (0.0795 to 0.0803)
    		 2.26 to 2.28 (0.0890 to 0.0898)
    1.81 to 1.83 (0.0713 to 0.0720)
    		 2.05 to 2.07 (0.0807 to 0.0815)
    		 2.29 to 2.31 (0.0902 to 0.0909)
    1.84 to 1.86 (0.0724 to 0.0732)
    		 2.08 to 2.10 (0.0819 to 0.0827)
    		 2.32 to 2.34 (0.0913 to 0.0921)
    1.87 to 1.89 (0.0736 to 0.0744)
    		 2.11 to 2.13 (0.0831 to 0.0839)
    		 -
    1.90 to 1.92 (0.0748 to 0.0756)
    		 2.14 to 2.16 (0.0843 to 0.0850)
    		 -


8. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE

  1. C120866E01
    Using a dial indicator, measure the runout of the companion flange vertically and horizontally.

    Maximum runout:
    0.09 mm (0.0035 in.)

    If the runout is greater than the maximum value, replace the rear drive pinion companion flange sub-assembly.


9. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

  1. C120867
    Using a torque wrench, measure the preload of the drive pinion.

    Preload (at starting):
    Specifications
    		 Drive pinion preload
    New bearing
    		 1.49 to 2.59 N*m (15.2 to 26.4 kgf*cm, 13.2 to 22.9 in.*lbf)
    Reused bearing
    		 1.11 to 1.91 N*m (11.3 to 19.5 kgf*cm, 9.8 to 16.9 in.*lbf)

    If the drive pinion preload is not within the specified range, adjust the drive pinion preload or repair as necessary.


10. INSPECT TOTAL PRELOAD

  1. C120867
    Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

    Preload (at starting):
    Specifications
    		 New drive pinion tapered roller bearing
    		 Reused drive pinion tapered roller bearing
    New differential case bearing
    		 2.57 to 4.26 N*m (26.2 to 43.4 kgf*cm, 22.7 to 37.7 in.*lbf)
    		 2.19 to 3.58 N*m (22.3 to 36.5 kgf*cm, 19.4 to 31.7 in.*lbf)
    Reused differential case bearing
    		 1.98 to 3.37 N*m (20.2 to 34.4 kgf*cm, 17.5 to 29.8 in.*lbf)
    		 1.60 to 2.69 N*m (16.3 to 27.4 kgf*cm, 14.2 to 23.8 in.*lbf)

    If the total preload is not within the specified range, adjust the total preload or repair as necessary.


11. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

  1. C120868E01
    Using SST, remove the 2 oil seals.
    SST
    09308-00010  


12. REMOVE REAR DRIVE PINION NUT

  1. C120869E01
    Using SST and a hammer, unstake the staked part of the drive pinion nut.
    SST
    09930-00010  

    NOTICE:
    1. Be sure to use SST with the tapered surface facing the shaft.
    2. Do not grind the tip of the SST with a grinder, etc.
    3. Completely loosen the staked part of the nut when removing it.
    4. Do not damage the threads of the drive pinion.

  1. C120871E01
    Using SST to hold the flange, remove the drive pinion nut.
    SST
    09330-00021  


13. REMOVE REAR DRIVE PINION COMPANION FLANGE

  1. C120873E01
    Using SST, remove the companion flange.
    SST
    09950-30012   (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)

    NOTICE:
    Apply grease to the threads and tip of the SST center bolt before use.


14. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR

HINT:
Perform this procedure only when the dust deflector is damaged.

  1. C126687E01
    Using SST and a press, remove the dust deflector.
    SST
    09950-00020  
    09950-60010   (09951-00380)
    09950-70010   (09951-07100)

    NOTICE:
    Do not drop the companion flange.


15. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

  1. C120878E01
    Using SST, remove the oil seal from the differential carrier.
    SST
    09308-00010  


16. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

  1. C126208
    Remove the drive pinion oil slinger.


17. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING

  1. C120880E01
    Using SST, remove the inner race of the rear drive pinion front tapered roller bearing from the drive pinion.
    SST
    09556-22010  

    NOTICE:
    Apply grease to the threads and tip of the SST center bolt before use.


18. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

  1. C120881
    Remove the drive pinion bearing spacer.


19. REMOVE DIFFERENTIAL CASE ASSEMBLY

  1. C120882E01
    Put matchmarks on either set of the bearing cap and differential carrier.

  1. Remove the 4 bolts and 2 bearing caps.

    NOTICE:
    Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.

  1. C120883E01
    Using SST and a hammer, remove the 2 side gear shaft plate washers.
    SST
    09504-22011  

    NOTICE:
    Put identification marks on the side gear shaft plate washer to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.

    HINT:
    Measure the thickness of the plate washers and note it.

  1. C120888
    Remove the differential case assembly and the case bearing outer races LH and RH from the differential carrier.

    NOTICE:
    1. Do not damage the differential case bearing or ring gear.
    2. Put identification marks on the case bearing outer race to show the location for installation (back side or teeth side), or keep them separate so that they can be distinguished.


20. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

  1. Remove the drive pinion from the differential carrier.

  1. C120984E01
    Using SST and a press, remove the inner race of the rear drive pinion rear tapered roller bearing from the drive pinion.
    SST
    09950-00020  

    NOTICE:
    Do not drop the drive pinion.

    HINT:
    If either the drive pinion or ring gear is damaged, replace both as a set.

  1. Remove the drive pinion plate washer from the drive pinion.

    HINT:
    Measure the thickness of the plate washer and note it.

  1. C120885E01
    Using a brass bar and a hammer, remove the outer race of the rear drive pinion front tapered roller bearing from the differential carrier.

    NOTICE:
    Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.


21. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING

  1. C120884E01
    Using a brass bar and a hammer, remove the outer race of the rear drive pinion rear tapered roller bearing from the differential carrier.

    NOTICE:
    Place the brass bar onto the outer race of the rear drive pinion front tapered roller bearing. Do not damage the differential carrier.


22. REMOVE DIFFERENTIAL RING GEAR

  1. C120986E01
    Hold the differential case in a vise between aluminum plates.

    NOTICE:
    Do not overtighten the vise.

  1. Put matchmarks on the ring gear and differential case.

  1. Using a chisel and a hammer, unstake the 5 lock plates.

  1. C123410
    Remove the 10 ring gear set bolts and 5 lock plates.

  1. C120886
    Using a plastic hammer, tap on the ring gear to separate it from the differential case.

    HINT:
    Use cloth to prevent damage to the ring gear teeth.


23. INSPECT RUNOUT OF DIFFERENTIAL CASE ASSEMBLY

HINT:
Perform this procedure only when the runout of the differential ring gear exceeds the specified maximum value.

  1. C120887
    Install the case bearing outer races LH and RH to the case bearing inner races LH and RH respectively.

    NOTICE:
    1. Be sure to install the bearing outer races in each correct position.
    2. Do not damage the differential case bearing or ring gear.

  1. Install the differential case to the differential carrier.

  1. Install the right and left (back side and teeth side) side gear shaft plate washers so that there is no looseness on the case bearings.

    C120989E01

  1. C123385E01
    Align the matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.

    NOTICE:
    Make sure that the right and left bearing caps are not interchanged.

  1. Tighten both bearing caps with the 4 bolts.

    Torque:
    85 N*m{ 870 kgf*cm , 63 ft.*lbf }

  1. C120895
    Using a dial indicator, measure the differential case runout.

    Maximum case runout:
    0.07 mm (0.0028 in.)

    If the runout is greater than the maximum value, replace the differential case assembly with a new one.

  1. Remove the 4 bolts and 2 bearing caps.

    NOTICE:
    Do not swap bearing caps, as each cap is only suitable for its original location and installation direction on the carrier it was manufactured on.

  1. Remove the right and left bearing caps, 2 side gear shaft plate washers and differential case.

    NOTICE:
    Do not damage the differential case bearing or ring gear.


24. REMOVE REAR DIFFERENTIAL CASE BEARING

HINT:
Perform this procedure only when replacing the case bearing or differential case.

  1. C120896E01
    Hold the differential case in a vise between aluminum plates.

    NOTICE:
    Do not overtighten the vise.

  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   (09951-00480, 09951-00350, 09952-06010)

    NOTICE:
    1. Do not deform the bearing cage if the bearing is to be reused.
    2. Hook the SST claw from the dent of the differential case to the bearing inner race.
    3. Apply grease to the threads and tip of the SST center bolt before use.

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