LEXUS ES300 2005 Repair Manual

C50242
Front Differential
Side Gear
Front
Differential
Side Gear
D25599
SST
D25600
SST
C50242
Front Differential
Side Gear
Front
Differential
Side Gear
C50241
Differential Case
Front Differential Pinion Shaft No.1
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 pinion thrust
washers, 2 front differential side gears and 2 side gear
thrust washers from the differential case.
7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950- 70010 (09951- 07100), 09215- 00013
(09215-00471)
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
9. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Apply the 2 front differential side gears, 2 side gear thrust
washers, 2 front differential pinions and 2 pinion thrust
washers with ATF and install them to the differential case.
10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
(a) Apply the front differential pinion shaft No.1 with ATF,
install it to the differential case.

C50252
C50253
C50254
D26447
SST
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSPECT BACKLASH
(a) Using a dial indicator, inspect the backlash of the side
gear.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness
MarkThickness
-1.625 mm (0.0640 in.)
-1.725 mm (0.0679 in.)
-1.825 mm (0.0719 in.)
12. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, install the pinion shaft
straight pin.
(b) Using a chisel and hammer, stake the differential case.
NOTICE:
Stake it after adjusting the backlash.
13. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
rear tapered roller bearing to the differential case.
SST 09316- 12010, 09550- 60010 (09951- 00490),
09950-70010 (09951-07100)
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.

C83736
D26448
SST
D26449
SST
D26450
Differential Assy
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST 09550- 60010 (09951- 00490), 09950- 60020
(09951-00910)
14. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
front tapered roller bearing to the differential case.
SST 09316- 12010, 09550- 60010 (09951- 00490),
09950-70010 (09951-07100)
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST 09950- 70010 (09951- 07150), 09950- 60020
(09951-00890)
NOTICE:
Clearance is not allowed between the bearing and trans-
axle housing.
15. ADJUST DIFFERENTIAL SIDE BEARING RRELOAD
(a) Install the differential assy to the transaxle case.

D26384
C
C
C
CAB
A
D25604
SST
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Clean the matching surfaces of the transaxle case and
transaxle housing.
(c) Install the transaxle housing to the transaxle case and
tighten them with the 16 bolts.
Torque:
Bolt A: 25 NVm (255 kgfVcm, 18 ftVlbf)
Bolt B: 33 NVm (337 kgfVcm, 24 ftVlbf)
Bolt C: 29 NVm (295 kgfVcm, 21 ftVlbf)
Bolt D: 22 NVm (226 kgfVcm, 16.0 ftVlbf)
HINT:
Apply seal packing or equivalent to the A and D.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it
can be used after cleaning it.
(d) Using SST, turn the differential assy right and left 2
or 3
times to settle the bearing.
SST 09564-3201 1
(e) Using SST and a torque wrench, measure the turning
torque of the differential.
SST 09564-3201 1
Turning torque at 60 rpm:
New bearing
0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
Used bearing
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
HINT:
If the turning torque is not within the specified value, refer to the
table below to select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)

D26384
D26450
Differential Assy
D25215
90 - 100
C (194 - 230
F)
D26445
Mark
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)Mark ThicknessMark Thickness
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
(f) Remove the 16 bolts and the transaxle housing.
(g) Remove the differential assy.
16. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90 - 110
C (194.0 - 230.0
F).
NOTICE:
Do not overheat the ring gear to 110
C (230.0
F) or more.
(b) Clean the contact surface of the front differential case.
(c) Align the match-marks, install the front differential ring
gear case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.

D26446
D26451
SST
D25606
SST
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Tighten the 14 bolts.
Torque: 95.0 NVm (970 kgfVcm, 70 ftVlbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
17. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
(b) Apply the rip of oil seal with a little MP grease.
SST 09223-15020, 09950-70010 (09951-07150)
Oil seal drive in depth: 0
0.5 mm (0
0.0197 in.)
18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, drive into a new oil seal.
(b) Apply the lip of the oil seal with a little MP grease.
SST 09710-30050, 09950-70010 (09951-07150)
Oil seal drive in depth: 0
0.5 mm (0
0.0197 in.)

4006N-02
C50182
Match-marks
Front Differential Ring Gear
C50183
Front Differential
Ring Gear
C50184Front Differential Ring Gear
C50187
Differential
Case Assy
Differential
LH Case
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
FRONT DIFFERENTIAL ASSY (U151F)
OVERHAUL
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match-marks on the ring gear and differential
case.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the case.
2. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the differential LH case from the differential case
assy.

C50188
Differential
Case No.2
Differential
Case LH
C50189
Differential
Case LH
Center
Differential
Side Gear
Thrust Washer
No.2Conical Spring
Front
Differential
Side Gear
Thrust WasherFront
Differential
Side Gear
D25610
C50190
C50191
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Remove the differential case No.2 from the differential
case LH.
(c) Remove the front differential side gear, front differential
side gear thrust washer, conical spring and center differ-
ential side gear thrust washer No.2 from the differential
case LH.
(d) Using a snap ring expander, remove the pinion shaft
spacer snap ring.
(e) Using a pin punch and a hammer, remove 3 straight pins.
(f) Remove the center differential pinion shaft and 2 differen-
tial pinion shafts.

C50943
D25597
SST
SST HoldTurn
D25598
SST
C50193
C50230
Differential
RH Case
Differential
Intermediate Case
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Remove 4 front differential pinions, 4 front differential pin-
ion thrust washers, front differential pinion shaft holder,
front differential planetary ring gear and differential side
gear thrust washer No. 1.
3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered
roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00480)
(b) Using SST, remove the front differential case rear tapered
roller bearing outer race and differential case washer.
SST 09308-00010
4. REMOVE CENTER DIFFERENTIAL PINION
(a) Using torx socket (T50), remove the 15 bolts.
(b) Place the matchmarks on the differential intermediate
case and differential case.
(c) Remove the differential intermediate case from the differ-
ential case RH.

C50196
Differential Case RH
Center Differential
Side Gear
C50194
D25611
SSTSST Hold
Turn
D25596
SST
D25599
SST
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the center differential side gear, conical spring
washer and center differential side gear thrust washer No.
1 RH from the differential case RH.
(e) Remove the differential spider, 5 center differential pin-
ions and 5 center differential pinion thrust washers from
the differential intermediate case.
5. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front ta-
pered roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00600)
(b) Using SST, remove the front differential case front ta-
pered roller bearing outer race and differential case wash-
er.
SST 09308-00010
6. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09649-17010