HF2A TRANSFER: CENTER DIFFERENTIAL: REASSEMBLY; 2007 MY LX470 [08/2006

Last Modified: 7-3-2017	6.8:8.0.40	Doc ID: RM0000018D8003X
Model Year Start: 2007	Model: LX470	Prod Date Range: [08/2006 - ]
Title: HF2A TRANSFER: CENTER DIFFERENTIAL: REASSEMBLY; 2007 MY LX470 [08/2006 - ]

REASSEMBLY

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL LOW GEAR

(a) Clean the contact surface of the differential case.

(b) Heat the low gear in boiling water.

(d) After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.

2. INSTALL PINION SHAFT, PINION GEAR AND THRUST WASHER

(a) Install the front side gear and thrust washer.

(b) Install the pinion shaft, 2 pinion gears and thrust washers to the front differential case.

HINT:

Push the pinion shaft.

Maximum backlash:

0.05 mm (0.0020 in.)

If the backlash is greater than the maximum, replace the thrust washer with one of the correct size and reinstall the thrust washer.

Standard snap ring thickness:

Thickness mm (in.)	Thickness mm (in.)
1.70 (0.0669)	2.45 (0.0965)
1.85 (0.0728)	2.60 (0.1024)
2.00 (0.0787)	2.75 (0.1083)
2.15 (0.0846)	2.90 (0.1142)
2.30 (0.0906)	3.05 (0.1201)

(d) Use the procedures described for the front case backlash to measure the rear case backlash.

(e) Install the straight pin to the pinion shaft.

3. INSTALL THRUST WASHER AND REAR SIDE GEAR

4. INSTALL REAR DIFFERENTIAL CASE

(a) Install the differential case with the 12 set bolts.

Torque:

88 N·m {900 kgf·cm, 65ft·lbf}

(b) Turn the pinion gear.

(d) Torque the 12 case set bolts.

Torque:

98 N·m {1,000 kgf·cm, 72ft·lbf}

5. INSTALL REAR TAPER ROLLER BEARING

(a) Using SST and a press, press in the taper roller bearing.

SST: 09316-12010

6. INSTALL CLUTCH HUB

(a) Using SST and a press, press in the clutch hub.

SST: 09316-12010

SST: 09316-60011

09316-00011

7. INSTALL HIGH SPEED OUTPUT GEAR BUSH

(a) Apply MP grease to the straight pin.

(b) Install the straight pin, as shown in the illustration.

SST: 09316-12010

SST: 09316-60011

09316-00011

NOTICE:

Before pressing on the front differential case, align the groove on the bushing with the pin on the shaft.

8. INSTALL HIGH AND LOW CLUTCH SLEEVE

HINT:

Make sure to install the high and low clutch sleeve in the correct direction.

9. INSTALL NEEDLE ROLLER BEARING AND HIGH SPEED OUTPUT GEAR

(a) Apply gear oil to the needle roller bearing.

(b) Install the needle roller bearing and high speed output gear.

10. INSTALL FRONT TAPER ROLLER BEARING

(a) Using SST and a press, press in the taper roller bearing.

SST: 09316-12010

SST: 09316-60011

09316-00011

11. INSTALL FRONT DRIVE GEAR PIECE

(a) Using SST and a press, press in the drive gear piece.

SST: 09316-12010

SST: 09316-60011

09316-00011

12. INSTALL SNAP RING

(a) Select a snap ring that will allow the minimum axial play.

Standard snap ring thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.00 (0.0787)	G	2.60 (0.1024)
B	2.10 (0.0827)	H	2.70 (0.1063)
C	2.20 (0.0866)	J	2.80 (0.1102)
D	2.30 (0.0906)	K	1.80 (0.0709)
E	2.40 (0.0945)	L	1.90 (0.0748)
F	2.50 (0.0984)	-	-

(b) Using a snap ring expander, install a new snap ring.

13. CHECK HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE