Lexus IS250 · Service Manual DRIVE LINE

REPLACEMENT

Removal / installation


1. REMOVE REAR WHEEL

2. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR

  1. G033363
    Remove the 2 nuts and No. 2 differential support protector from the suspension member brace.


3. DRAIN DIFFERENTIAL OIL

  1. Using a hexagon wrench (10 mm), remove the differential filler plug and gasket.

  1. Using a hexagon wrench (10 mm), remove the differential drain plug and gasket, and drain the oil.

  1. Using a hexagon wrench (10 mm), install the differential drain plug and a new gasket.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }


4. REMOVE REAR NO. 1 FLOOR PANEL BRACE

  1. A121036
    Remove the 4 bolts and rear No. 1 floor panel brace.


5. REMOVE FRONT CENTER FLOOR BRACE

  1. C104834
    Remove the 4 bolts and front center floor brace .


6. DISCONNECT HEATED OXYGEN SENSOR

  1. A120539E09
    Remove the grommets of the heated oxygen sensors (BANK 1, BANK 2).

  1. A120540E03
    Using the SST, remove a oxygen sensors (BANK 1, BANK 2).
    SST
    09224-00010  


7. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  1. A127822E01
    Remove the 4 bolts and 4 nuts.

  1. A125008
    Remove the 2 bolts and 2 compression springs from the tail exhaust pipe assembly.

  1. Remove the front exhaust pipe assembly and 3 gaskets.


8. REMOVE TAIL EXHAUST PIPE ASSEMBLY

  1. A125037E02
    Disconnect the 6 exhaust pipe supports to remove the tail exhaust pipe assembly.


9. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
(Click here)

10. REMOVE REAR SUSPENSION MEMBER BRACE LH

  1. C120172E01
    Remove the 2 bolts and rear suspension member brace LH.


11. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY

  1. Remove the 3 bolts and disengage the 2 clamps and No. 3 parking brake cable assembly LH.

    C121222

  1. Separate the No. 3 parking brake cable assembly LH from the parking brake equalizer.


12. SEPARATE REAR STABILIZER LINK ASSEMBLY LH

  1. C104507
    Remove the bolt and nut, and separate the load sensing valve sensor bracket and stabilizer link assembly.


13. REMOVE REAR AXLE SHAFT NUT

  1. C102816E02
    Using SST and a hammer, release the staked part of the axle shaft nut.
    SST
    09930-00010  

    NOTICE:
    Release the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged.

  1. Remove the rear axle shaft nut.


14. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY

  1. G032829
    Remove the 2 bolts, and disconnect the rear disc brake caliper assembly.

    NOTICE:
    Use wire or equivalent to prevent the brake caliper from hanging down by the flexible hose.

  1. Remove the No.1 caliper plates from the brake caliper.


15. SEPARATE REAR SPEED SENSOR

  1. C101201J02
    Remove the 2 bolts, and separate the speed sensor from the axle carrier.

    NOTICE:
    1. Be careful not to damage the speed sensor.
    2. Prevent foreign matter from adhering to the speed sensor.


16. SEPARATE NO. 2 REAR UPPER CONTROL ARM ASSEMBLY

  1. Remove the nut from the No. 2 upper control arm assembly rear.

  1. C104831E02
    Using SST, separate the No. 2 upper control arm assembly rear from the rear axle carrier sub-assembly.
    SST
    09628-00011  

    NOTICE:
    1. Use caution not to damage the rear axle carrier because it is made of aluminum and may be damaged easily.
    2. Do not damage the ball joint dust cover.
    3. Make sure that the SST is securely positioned on the rear axle carrier spacer.
    4. If the rear axle carrier spacer has come off, replace the rear axle carrier with a new one.
    5. Make sure that the string of the SST is securely tied to the vehicle.


17. SEPARATE NO. 1 REAR UPPER CONTROL ARM ASSEMBLY

  1. Jack up the rear axle assembly so that the bolt on the No. 1 upper control arm assembly rear can be removed.

    HINT:
    Place a wooden block between the jack and rear axle carrier to prevent damage to the rear axle carrier.

  1. C104512
    Remove the bolt, washer and nut, and separate the No. 1 upper control arm assembly rear from the rear axle carrier sub-assembly.


18. SEPARATE NO. 1 REAR SUSPENSION ARM ASSEMBLY

  1. C104514E02
    Remove the bolt and nut, and separate the No. 1 rear suspension arm assembly from the rear axle carrier sub-assembly.

    NOTICE:
    Turn the bolt while holding the nut.


19. SEPARATE NO. 2 REAR SUSPENSION ARM ASSEMBLY

  1. C104515E03
    Remove the bolt and nut, and separate the No. 2 rear suspension arm assembly from the rear axle carrier sub-assembly.

    NOTICE:
    Turn the bolt while holding the nut.


20. SEPARATE TOE CONTROL LINK SUB-ASSEMBLY

  1. Remove the nut from the toe control link sub-assembly.

  1. C103050E03
    Using SST, separate the toe control link sub-assembly from the rear axle carrier sub-assembly.
    SST
    09628-00011  

    NOTICE:
    1. Use caution not to damage the rear axle carrier because it is made of aluminum and may be damaged easily.
    2. Do not damage the ball joint dust cover.
    3. Make sure that the SST is securely positioned on the rear axle carrier spacer.
    4. If the rear axle carrier spacer has come off, replace the rear axle carrier with a new one.
    5. Make sure that the string of the SST is securely tied to the vehicle.


21. REMOVE REAR AXLE ASSEMBLY

  1. Using a plastic hammer, separate the drive shaft from the rear axle assembly.

    NOTICE:
    1. Be careful not to damage the boot.
    2. Use wire or equivalent to prevent the rear drive shaft assembly from hanging down.


22. REMOVE REAR DRIVE SHAFT ASSEMBLY

  1. C102817E01
    Using SST, remove the rear drive shaft assembly.
    SST
    09520-01010  
    09520-24010   (09520-32040)

    NOTICE:
    1. Be careful not to damage the oil seal, inboard joint boot and drive shaft dust cover.
    2. Be careful not to drop the drive shaft assembly.


23. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

  1. C127015E01
    Using SST, remove the oil seal.
    SST
    09308-10010  


24. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

  1. C123424E01
    Using SST and a hammer, install a new oil seal.
    SST
    09213-70011  
    09950-60010   (09951-00410, 09951-00620, 09952-06010)
    09950-70010   (09951-07100)

    Oil seal installation depth:
    -0.5 to 0.5 mm (-0.020 to 0.020 in.)

  1. Apply MP grease to the oil seal lip.


25. INSTALL REAR DRIVE SHAFT ASSEMBLY

  1. Coat the spline of the inboard joint shaft assembly with gear oil.

  1. Set the shaft snap ring with the opening side facing down.

  1. C104526
    Align the shaft splines and install the drive shaft assembly with a brass bar and hammer.

    NOTICE:
    1. Be careful not to damage the drive shaft dust cover, boot and oil seal.
    2. Move the drive shaft assembly while keeping it level.

    HINT:
    It is possible to determine if the inboard joint shaft is properly engaged (the shaft is in contact with the pinion shaft, and the snap ring is engaged in the pinion gear) based on the sound or feeling when the shaft is driven in.

  1. Install the rear drive shaft assembly to the rear axle carrier.

    NOTICE:
    Be careful not to damage the drive shaft boot.


26. INSTALL REAR AXLE ASSEMBLY

  1. Install the rear drive shaft assembly and rear axle assembly.


27. INSTALL NO. 2 REAR UPPER CONTROL ARM ASSEMBLY

  1. C104511J01
    Install the No. 2 rear upper control arm assembly to the rear axle carrier sub-assembly with a new nut.

    Torque:
    70 N*m{ 714 kgf*cm , 52 ft.*lbf }


28. TEMPORARILY TIGHTEN NO. 1 REAR UPPER CONTROL ARM ASSEMBLY

  1. C104512J01
    Temporarily tighten the No. 1 rear upper control arm assembly to the rear axle carrier sub-assembly with the bolt, washer and nut.

    HINT:
    Install the bolt from the rear side of the vehicle and lightly tighten the bolt.


29. TEMPORARILY TIGHTEN NO. 1 REAR SUSPENSION ARM ASSEMBLY

  1. C102991E01
    Temporarily tighten the No. 1 rear suspension arm assembly to the rear axle carrier sub-assembly with the bolt and nut.

    HINT:
    Install the bolt from the rear side of the vehicle and lightly tighten the bolt.


30. TEMPORARILY TIGHTEN NO. 2 REAR SUSPENSION ARM ASSEMBLY

  1. C102992E01
    Temporarily tighten the No. 2 rear suspension arm assembly to the rear axle carrier sub-assembly with the bolt and nut.

    HINT:
    Install the bolt from the rear side of the vehicle and lightly tighten the bolt.


31. INSTALL TOE CONTROL LINK SUB-ASSEMBLY

  1. C104513
    Install the toe control link sub-assembly to the rear axle carrier sub-assembly with a new nut.

    Torque:
    70 N*m{ 714 kgf*cm , 52 ft.*lbf }


32. INSTALL REAR STABILIZER LINK ASSEMBLY

  1. C104507
    Install the stabilizer link assembly and the load sensing valve sensor bracket to the No. 2 rear suspension arm assembly with the bolt and nut.

    Torque:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }


33. INSTALL REAR SPEED SENSOR

  1. C101201E01
    Install the speed sensor to the rear axle carrier with the 2 bolts.

    Torque:
    Bolt (A):
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }
    Bolt (B):
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

    NOTICE:
    1. Be careful not to damage the speed sensor.
    2. Prevent foreign matter from adhering to the speed sensor.
    3. Do not twist the sensor wire when installing the speed sensor.


34. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY

  1. G032829
    Install the rear disc brake caliper assembly and No. 1 caliper plates with the 2 bolts.

    Torque:
    54 N*m{ 551 kgf*cm , 40 ft.*lbf }

    NOTICE:
    1. Do not twist the rear brake hose when installing the rear disc brake caliper.
    2. Make sure that there are no foreign objects or damage to the threads.
    3. Do not overtighten the bolts because the hub carrier is made of aluminum and may be damaged.


35. INSTALL REAR AXLE SHAFT NUT

  1. Install a new axle shaft nut.

    Torque:
    290 N*m{ 2,957 kgf*cm , 214 ft.*lbf }

  1. C102818
    Using a chisel and a hammer, stake the axle shaft nut.


36. STABILIZE SUSPENSION

  1. Install the rear wheels.

  1. Lower the vehicle to the ground. Bounce the vehicle up and down at the corners to stabilize the rear suspension.

  1. Remove the rear wheels.

  1. C106394
    Jack up the axle carrier, with a wooden block placed between the jack and axle carrier, to apply a load to the suspension so that the rear drive shaft assembly becomes level.


37. FULLY TIGHTEN NO. 1 REAR UPPER CONTROL ARM ASSEMBLY

  1. C104508
    Fully tighten the No. 1 rear upper control arm assembly with the nut.

    Torque:
    161 N*m{ 1,642 kgf*cm , 119 ft.*lbf }


38. FULLY TIGHTEN NO. 1 REAR SUSPENSION ARM ASSEMBLY

  1. C101948
    Fully tighten the No. 1 rear suspension arm assembly with the bolt and nut.

    Torque:
    95 N*m{ 969 kgf*cm , 70 ft.*lbf }

    NOTICE:
    Turn the bolt while holding the nut.


39. FULLY TIGHTEN NO. 2 REAR SUSPENSION ARM ASSEMBLY

  1. C104509
    Fully tighten the No. 2 rear suspension arm assembly with the bolt and nut.

    Torque:
    161 N*m{ 1,642 kgf*cm , 119 ft.*lbf }

    NOTICE:
    Turn the bolt while holding the nut.


40. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY

  1. Connect the No. 3 parking brake cable assembly to the parking brake equalizer.

    C121222E01

  1. Install the No. 3 parking brake cable assembly to the body with the 3 bolts and 2 clamps.

    Torque:
    Bolt (A):
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }
    Bolt (B):
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }


41. INSTALL REAR SUSPENSION MEMBER BRACE LH

  1. C120172E01
    Install the rear suspension member brace LH with the 2 bolts.

    Torque:
    50 N*m{ 510 kgf*cm , 37 ft.*lbf }


42. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
(Click here)

43. INSTALL TAIL EXHAUST PIPE ASSEMBLY

  1. A125037E02
    Install the tail exhaust pipe assembly with the 6 exhaust pipe supports.


44. INSTALL FRONT EXHAUST PIPE ASSEMBLY

  1. A077857
    Using a vernier caliper, measure the free length of the compression springs.

    Minimum length:
    38.5 mm (1.516 in.)

    If the free length is less than the minimum, replace the compression spring.

  1. A109513E09
    Install a new gasket to the rear end of the front exhaust pipe.

    NOTICE:
    1. Be careful with the installation direction of the gasket.
    1. Do not reuse the gasket.
    1. To ensure a proper seal, do not use the tail exhaust pipe to force the gasket onto the front exhaust pipe.

      HINT:
      Using a plastic hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

  1. Install 3 new gaskets and front exhaust pipe assembly.

    CAUTION:
    Do not reuse the gaskets.

  1. A125008
    Install the 2 bolts and 2 compression springs.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }

  1. A127822E01
    Install 4 new nuts and 4 bolts.

    Torque:
    62 N*m{ 632 kgf*cm , 46 ft.*lbf }

    NOTICE:
    Do not reuse the nuts.


45. INSTALL HEATED OXYGEN SENSOR

  1. A119092
    Before installing the heated oxygen sensors, twist the sensor wires counterclockwise 4 turns.

  1. A123663E02
    Using the SST, install the heated oxygen sensors to the front exhaust pipe.
    SST
    09224-00010  

    Torque:
    44 N*m{ 449 kgf*cm , 33 ft.*lbf }

  1. After installing the sensors, check that the sensor wires are not twisted.
    If the sensor wires are twisted, reinstall them.

  1. A120539E05
    Install the grommets of the heated oxygen sensors.


46. INSTALL FRONT CENTER FLOOR BRACE

  1. C104834
    Install the front center floor brace with the 4 bolts.

    Torque:
    7.4 N*m{ 75 kgf*cm , 65 in.*lbf }


47. INSTALL REAR NO. 1 FLOOR PANEL BRACE

  1. A121036
    Install the rear No. 1 floor panel brace with the 4 bolts.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }


48. ADD DIFFERENTIAL OIL

  1. Using a hexagon wrench (10 mm), remove the differential filler plug and gasket.

  1. C104414
    Add oil.

    Capacity:
    1.10 to 1.20 liter (1.17 to 1.27 US qts, 0.97 to 1.05 lmp. qts)

    Oil grade:
    Toyota genuine differential synthetic gear oil API GL-5 SAE 75W-85 or equivalent

  1. Check the oil level.

  1. Using a hexagon wrench (10 mm), install the differential filler plug with a new gasket.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }

    NOTICE:
    After replacing the oil, recheck the oil level after driving.


49. INSPECT DIFFERENTIAL OIL

  1. Stop the vehicle on a level place.

  1. C120239
    Using a hexagon wrench (10 mm), remove the differential filler plug and gasket.

  1. D025304E04
    Check that the oil surface is within 5 mm (0.20 in.) of the lowest position of the inner surface of the differential filler plug opening.

    NOTICE:
    1. Excessively large or small amounts of oil may cause trouble.
    2. After replacing oil, recheck the oil level after driving.

  1. Check for oil leakage if the oil level is low.

  1. Using a hexagon wrench (10 mm), install the differential filler plug and a new gasket.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }


50. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR

  1. G033363
    Install the No. 2 differential support protector to the rear suspension member brace with the 2 nuts.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }


51. INSTALL REAR WHEEL

Torque:
103 N*m{ 1,050 kgf*cm , 76 ft.*lbf }


52. INSPECT PARKING BRAKE PEDAL TRAVEL (for Automatic Transmission)

  1. Fully depress the parking brake pedal and release it to engage the parking brake.

  1. Depress the pedal to the floor again, and release it to disengage the parking brake.

  1. C107204
    Slowly depress the parking brake pedal to the floor, and count the number of clicks.

    Parking brake pedal travel:
    7 to 9 notches at 300 N (31 kgf, 67.5 lbf)


53. ADJUST PARKING BRAKE PEDAL TRAVEL (for Automatic Transmission)

  1. Depress the parking brake pedal. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut.

  1. Release the parking brake pedal.

  1. C106337E02
    Turn the No. 1 wire adjusting nut until the parking brake pedal travel meets the above specification.

  1. Hold the wire adjusting No. 1 nut using a wrench or equivalent tool and tighten the lock nut.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

  1. Count the number of clicks after depressing and releasing the parking brake pedal 3 or 4 times.

  1. Check whether the parking brake drags or not.

  1. When operating the parking brake pedal, check that the parking brake indicator light comes on.


54. INSPECT PARKING BRAKE LEVER TRAVEL (for Manual Transmission)

  1. Pull firmly on the parking brake lever.

  1. Release the parking brake lock, and return the parking brake lever to its off position.

  1. C121749
    Slowly pull the parking brake lever all the way up, and count the number of clicks.

    Parking brake lever travel:
    4 to 6 notches at 200 N (20 kgf, 45 lbf)


55. ADJUST PARKING BRAKE LEVER TRAVEL (for Manual Transmission)

  1. Depress the parking brake lever. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut.

  1. Release the parking brake lever.

  1. C124880E01
    Turn the No. 1 wire adjusting nut until the parking brake lever travel meets the above specification.

  1. Hold the No. 1 wire adjusting nut using a wrench or equivalent tool and tighten the lock nut.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

  1. Count the number of clicks after depressing and releasing the parking brake lever 3 or 4 times.

  1. Check whether the parking brake drags or not.

  1. When operating the parking brake lever, check that the parking brake indicator light comes on.


56. CHECK FOR EXHAUST GAS LEAKAGE

57. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
(Click here)

58. CHECK ABS SPEED SENSOR SIGNAL
(Click here)
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