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Home >> Lexus >> 2005 >> GX 470 V8-4.7L (2UZ-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Service and Repair >> Overhaul (Front Differential) >> Part 1

Part 1

OVERHAUL

HINT:
COMPONENTS: See Diagrams; Exploded Views.

1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1
3. REMOVE ENGINE UNDER COVER ASSEMBLY REAR
4. DRAIN DIFFERENTIAL OIL
5. REMOVE PROPELLER SHAFT ASSEMBLY FRONT
6. REMOVE SPEED SENSOR FRONT RH
7. REMOVE SPEED SENSOR FRONT LH

HINT: Remove the RH side by the same procedures with the LH side

8. REMOVE FRONT AXLE HUB GREASE CAP LH
9. REMOVE FRONT AXLE HUB GREASE CAP RH

HINT: Remove the RH side by the same procedures with the LH side

10. REMOVE FRONT AXLE HUB LH NUT
11. REMOVE FRONT AXLE HUB RH NUT

HINT: Remove the RH side by the same procedures with the LH side

12. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
13. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT: Remove the RH side by the same procedures with the LH side.

14. SEPARATE TIE ROD END SUB-ASSEMBLY LH
SST 09628-62011
15. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT: Remove the RH side by the same procedures with the LH side.

SST 09628-62011
16. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
17. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: Remove the RH side by the same procedures with the LH side.

18. SEPARATE FRONT AXLE ASSEMBLY LH
19. SEPARATE FRONT AXLE ASSEMBLY RH

HINT: Remove the RH side by the same procedures with the LH side.

20. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
SST 09520-01010, 09520-24010 (09520-32040)
21. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

HINT: Remove the RH side by the same procedures with the LH side

SST 09520-01010, 09520-24010 (09520-32040)
22. REMOVE DIFFERENTIAL CARRIER ASSEMBLY FRONT





a. Remove the bolt and separate the front differential breather tube bracket.
b. Support the front differential with a jack.
c. Remove the front differential mount nut No.1.
d. Remove the 2 front mounting bolts and 2 nuts.
e. Lower the jack and remove the front differential assembly.
f. Remove the 2 bolts and front differential support No.3.
g. Remove the 5 bolts and 2 front differential supports.
23. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION





a. Using SST and a dial indicator, measure the ring gear backlash.
SST 09564-32011
Backlash: 0.11 - 0.18 mm (0.0043 - 0.0071 inch)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
24. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT





a. Using a dial indicator measure the runout of the companion flange vertically and horizontally.
Maximum runout:
Vertical runout: 0.10 mm (0.0039 inch)
Lateral runout: 0.10 mm (0.0039 inch)
If the runout is greater than the maximum, replace the companion flange
25. INSPECT DRIVE PINION PRELOAD





a. Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
0.49 - 0.78 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
26. INSPECT TOTAL PRELOAD





a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.20 - 0.63 Nm (2 - 6 kgf-cm, 1.8 - 5.6 inch lbs.)
If necessary, disassemble and inspect the differential.
27. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY





a. Remove the 4 bolts.
b. Using a plastic hammer, remove the differential tube.
28. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL





a. Using SST, remove the side oil seal.
SST 09308-00010
29. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT





a. Using SST and a hammer, unstake the nut.
SST 09930-00010





b. Using SST to hold the companion flange, remove the nut.
SST 09330-00021
30. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT





a. Using SST, remove the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
31. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR





a. Using SST and a press, remove the dust deflector
SST 09950-00020, 09950-60010 (09951-00510), 09950-70010 (09951-07150)
32. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL





a. Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
33. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
34. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING





a. Using SST, remove the tapered roller bearing (inner) the drive pinion.
SST 09556-22010
b. Remove the bearing spacer.
35. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
a. Remove the 10 bolts and tap out the retainer with a plastic hammer.
36. REMOVE DIFFERENTIAL CASE ASSEMBLY
37. REMOVE DIFFERENTIAL DRIVE PINION
38. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING





a. Using SST and a press, remove the tapered roller bearing (inner) and washer from the drive pinion.
SST 09950-00020

HINT: If the drive or ring gear are damaged, replace them as a set.

39. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING





a. Using a brass bar and hammer, remove the tapered roller bearing (outer).
40. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING





a. Using SST, remove the rear tapered roller bearing (outer).
SST 09502-12010, 09612-65014 (09612-01020, 09612-01050)
41. REMOVE FRONT DIFFERENTIAL OIL STORAGE RING
a. Using a brass bar and hammer, remove the oil storage ring.
42. REMOVE FRONT DIFFERENTIAL CASE BEARING

HINT:
^ Measure the case washer and note the thickness.
^ Tag the bearing outer races to show the location for reassembly.





a. Using SST and a press, remove the case bearing (outer) and plate washer from the bearing retainer.
SST 09950-60020 (09951-00680), 09950-70010 709951-07150)





b. Using SST and a press, remove the case bearing (outer) and plate washer from the differential carrier assembly.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
43. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on the ring gear and differential case.
b. Remove the 10 bolts.





c. Using a plastic hammer, tap on the ring gear to separate it from the differential case.
44. REMOVE FRONT DIFFERENTIAL CASE BEARING





a. Using SST, remove the 2 case differential case bearing (inner) from the differential case assembly.
SST 09950-60010 (09951-00480), 09950-40011, (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09953-04020, 09958-04011)
45. DISASSEMBLE DIFFERENTIAL CASE





a. using the chisel and hammer, cancellation lock of the differential case.





b. Using a punch and hammer, remove the straight pin.





c. Remove these parts from the differential case.
1. Differential pinion gear (2 pieces)
2. Differential pinion gear thrust washer (2 pieces)
3. Differential pinion shaft
4. Differential side gear (2 pieces)
5. Differential side gear thrust washer (2 pieces)
46. INSPECT DIFFERENTIAL GEAR KIT
a. Check that no damage is identified on the differential pinion and differential side gear.
If the differential pinion and/or differential side gear is damaged, replace the differential gear kit.
47. INSPECT FRONT DIFFERENTIAL CASE
a. Check that no damaged is differential case.
If the differential case is damaged, replace the differential case.
48. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL





a. Using SST, remove the oil seal from the differential tube.
SST 09308-00010
49. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH





a. Using a snap ring expander, remove the snap ring.
b. Remove the shaft from the differential tube.
50. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING
a. Using a snap ring expander, remove the snap ring.





b. Using SST, a brass bar and press, remove the shaft RH bearing.
SST 09950-00020

NOTICE: Do not damage the bearing.

51. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING





a. Using SST and a press, install a new shaft RH bearing.
SST 09223-00010
b. Using a snap ring expander, install the snap ring.
52. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH
a. Install the shaft into the differential tube.





b. Using needle nose pliers, install the snap ring.
53. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL





a. Using SST and plastic hammer, install a new oil seal.
SST 09223-15020
Oil seal drive in depth: 5.3 ± 0.5 mm (0.209 ± 0.0197 inch)
b. Coat the oil seal lip with MP grease.
54. INSTALL FRONT DIFFERENTIAL CASE





a. Install the 2 proper thrust washers on the 2 side gears.

HINT: Using the table, select 2 thrust washers which will ensure that the backlash is within the specifications.





Washer thickness

b. Install the 2 side gears, 2 pinion gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion thrust washers and pinion shaft in the differential case assembly.

HINT: Align the holes of the differential case and pinion shaft.

c. Measure the side gear backlash.





1. Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the differential case.
Backlash: 0 - 0.15 mm (0 - 0.00591 inch)
If the backlash is not within the specification, install 2 side gear thrust washers with different thicknesses.





d. Using a pin punch and hammer, install the straight pin through the differential case and hole of the pinion shaft.
e. Stake the differential case.
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