DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY: DISASSEMBLY; 2007 MY LX470 [08/2006

Last Modified: 7-3-2017	6.8:8.0.40	Doc ID: RM000001ADD005X
Model Year Start: 2007	Model: LX470	Prod Date Range: [08/2006 - ]
Title: DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY: DISASSEMBLY; 2007 MY LX470 [08/2006 - ]

DISASSEMBLY

1. REMOVE FRONT DIFFERENTIAL CARRIER COVER

(a) Remove the 9 bolts and nut from the carrier cover.

(b) Using a brass bar and hammer, separate the cover from the carrier.

(d) Remove the 2 bolts and oil deflector from the differential carrier cover.

2. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using a dial indicator, measure the vertical runout of the companion flange.

Maximum runout:

0.14 mm (0.0055 in.)

If the runout is greater than the maximum, replace the companion flange.

3. INSPECT RING GEAR RUNOUT

(a) Using a dial indicator, measure the ring gear runout.

Maximum runout:

0.07 mm (0.0028 in.)

If the runout is greater than the maximum, replace the ring gear and drive pinion as a set.

4. INSPECT RING GEAR BACKLASH

(a) Using a dial indicator, while holding the drive pinion flange measure the ring gear backlash.

Standard backlash:

0.13 to 0.18 mm (0.0051 to 0.0071 in.)

HINT:

Measure at 3 or more places on the circumference of the ring gear.

If the backlash is not within the specification, adjust the backlash.

5. INSPECT DRIVE PINION PRELOAD

(a) Using a torque wrench, measure the drive pinion preload using the backlash of the drive pinion and ring gear.

Torque:

Standard preload (at start of torque) -

0.6 to 0.9 N·m {6 to 9 kgf·cm, 4.3 to 6.9in·lbf}

6. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the total preload.

Torque:

Standard total preload (at start of torque) -

0.4 to 0.6 N·m {4 to 6 kgf·cm, 3.5 to 5.2in·lbf} + drive pinion preload

If necessary, disassemble and inspect the differential.

7. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

8. REMOVE SIDE GEAR SHAFT OIL SEAL

(a) Using SST, remove the 2 side gear shaft oil seals.

SST: 09308-00010

9. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY

(a) Using SST, remove the snap ring.

SST: 09350-30020

09350-07060

(b) Using a snap ring expander, remove the snap ring.

(d) Remove the side gear shaft from the differential tube.

10. REMOVE DIFFERENTIAL SIDE GEAR SHAFT BEARING

(a) Using SST and a press, remove the bearing from side gear shaft.

SST: 09950-60010

09951-00410

SST: 09950-70010

09951-07100

11. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using a chisel and hammer, unstake the nut.

(b) Using SST to hold the flange, remove the nut.

SST: 09330-00021

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020

12. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST, remove the oil seal from the differential carrier.

SST: 09308-10010

13. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

(a) Remove the oil slinger.

14. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST, remove the rear bearing from the drive pinion.

SST: 09556-22010

If the rear bearing is damaged or worn, replace the rear bearing.

15. REMOVE FRONT DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Place matchmarks on the bearing cap and differential carrier.

(b) Remove the 4 bolts and 2 bearing caps.

SST: 09504-22011

HINT:

Measure the plate washer and note the thickness.

(d) Remove the differential case with the bearing outer races from the differential carrier.

HINT:

Tag the bearing outer races to show the location for reassembling.

16. REMOVE DRIVE PINION SUB-ASSEMBLY

17. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

18. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, remove the front bearing from the drive pinion.

SST: 09950-00020

HINT:

If the drive pinion or ring gear is damaged, replace them as a set.

(b) Remove the washer.

19. REMOVE REAR BEARING OUTER RACE

(a) Using SST, remove the rear bearing outer race.

SST: 09308-00010

(b) Using a brass bar and hammer, remove the oil storage ring and front bearing outer race.

20. REMOVE DIFFERENTIAL RING GEAR

(a) Place matchmarks on the ring gear and differential case.

(b) Using a screwdriver and hammer, unstake the 5 lock plates.

(d) Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.

21. INSPECT DIFFERENTIAL CASE

(a) Place the bearing outer races on their respective bearings. Check that the left and right outer races are not interchanged.

(b) Install the assembled plate washers onto the side bearing.

HINT:

If it is difficult to install the differential case into the carrier, replace the plate washer with a thinner one.

However, select a plate washer that allows no clearance between it and the carrier.

(d) Align matchmarks on the bearing cap and differential carrier.

(e) Install and uniformly tighten the 4 bolts a little at a time.

(f) Using a dial indicator, measure the differential case runout.

Maximum runout:

0.07 mm (0.0028 in.)

If the runout is greater that the maximum, replace the differential case and side bearings as a set.

(g) Remove the differential case.

22. REMOVE FRONT DIFFERENTIAL CASE BEARING

(a) Using SST, remove the 2 side bearings from the differential case.

SST: 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04061

09957-04010

09958-04011

SST: 09950-60010

09951-00480

HINT:

Fix the claws of SST to the notches in the differential case.

23. DISASSEMBLE DIFFERENTIAL CASE

(a) Place matchmarks on the LH and RH case.

(b) Remove the 8 bolts uniformly, a little at a time.

(d) Remove the spider, 2 side gears, side gear thrust washers, 4 pinion gears and pinion gear thrust washers from the RH differential case.