differential LEXUS GS400 2000 Service Service Manual

SA1279
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA±71
2071 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
23. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove these parts from the differential case:

Pinion shaft

2 pinion gears

2 pinion gear thrust washers

2 side gears

2 side gear thrust washers

SA0SE±01
R15896
SST
SA1173
SST
R09980
SST
R15895
SST
SA1176
SA±72
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2072 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REPLACEMENT
1. REPLACE COMPANION FLANGE DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector.
SST 09950±00020, 09950±60010 (09951±00510)
(b) Using SST and a press, install a new dust deflector.
SST 09316±60011 (09316±00011)
2. REPLACE SIDE GEAR SHAFT DUST COVER
(a) Using SST and a press, remove the dust cover.
SST 09950±00020
(b) Using SST and a press, install a new dust cover.
SST 09502±24010, 09950±60020 (09951±00780),
09950±70010 (09951±07150)
HINT:
If the dust cover does not fit snugly against the flange of the side
gear shaft, use a screwdriver to drive it down.

SA1181
SA0SF±03
SA1178
W02619
SA1280
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA±73
2073 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REASSEMBLY
1. ADJUST DIFFERENTIAL PINION GEAR BACKLASH
(a) Install the 2 proper thrust washers on the side gears.
HINT:
Using the table below, select thrust washers which will ensure
that the backlash is within the specification.
Thrust washer thickness:
Thickness mm (in.)Thickness mm (in.)
1.50 (0.059)1.75 (0.069)
1.55 (0.061)1.80 (0.071)
1.60 (0.063)1.85 (0.073)
1.65 (0.065)1.90 (0.075)
1.70 (0.067)±
(b) Install the 2 side gears, pinion gears, pinion gear thrust
washers and pinion shaft in the differential case.
HINT:
Align the holes of the differential case and pinion shaft.
(c) Push the 2 side gear shafts gently into the differential
case by hand and install them.
(d) Using a dial indicator, measure the pinion gear backlash
with holding one side gear toward the case.
Maximum: 0.15 mm (0.0059 in.)
NOTICE:
Differential gears should be able to rotate.
If the backlash is not within the specification, install the 2 side
gear thrust washers with different thicknesses.
(e) Remove the 2 side gear shafts.
2. INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL
CASE
(a) Using a pin punch and hammer, install the straight pin
through the differential case and hole of the pinion shaft.
(b) Stake the differential case.

SA1143
Boiling Water
SA1158
Matchmarks
SA1148
SA1180
60 ± 90° 64 N´m (650 kgf´cm, 47 ft´lbf)
R15897
SST
SST SA±74
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2074 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and the
threads of the ring gear and differential case.
(b) Heat the ring gear in boiling water.
(c) Carefully remove the ring gear from the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the ring gear and the differential case.
(e) Tighten 2 of the bolts temporarily so that the bolt holes in
the ring gear and differential case are not misaligned.
NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
4. INSTALL RING GEAR SET BOLTS
(a) After the ring gear has cooled sufficiently, install new 10
ring gear set bolts to which thread lock has been applied.
Thread lock:
Part No. 08833±00100, THREE BOND 1360 K or equiv-
alent.
NOTICE:
New ring gear set bolts should be used in every case.
(b) Torque the 10 set bolts uniformly and a little at a time.
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
(c) Tighten the bolts further by 60 ± 90°.
NOTICE:
Tighten the bolts in diagonally opposite pairs.
5. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 side bearings.
SST 09710±30050, 09950±60010 (09951±00450),
09950±70010 (09951±07150)

R15898
SST
SST
R00055
SST
R00045SST
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA±75
2075 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
6. INSTALL DRIVE PINION BEARING OUTER RACES
AND ADJUSTING WASHER
HINT:

The adjusting washer is used for adjusting the tooth con-
tact pattern. 42 types of washer with different thicknesses
are available.

First fit a washer with the same thickness as the washer
which was removed, then after checking the tooth contact
pattern, replace the washer with one of a different thick-
ness if necessary.

When removing an adjusting washer, be sure to replace
it with a new one.
(a) Using SST and a press, install the front bearing outer
race.
SST 09950±60020 (09951±00710),
09950±70010 (09951±07150)
(b) Using SST and a press, install a new adjusting washer to
the rear bearing outer race.
SST 09255±10012, 09950±70010 (09951±07150)
7. INSTALL REAR BEARING TO DRIVE PINION
Using SST and a press, install the rear bearing.
SST 09502±24010
8. TEMPORARILY INSTALL DRIVE PINION, FRONT
BEARING, OIL SLINGER AND COMPANION FLANGE
(a) Install the drive pinion in the differential carrier.
(b) Using SST and a press, install the front bearing on the
drive pinion.
SST 09316±60011 (09316±00011), 09608±04031
HINT:
Assemble the spacer and oil seal after adjusting the tooth con-
tact pattern.
(c) Install the oil slinger.

SA1130
SST
SST
R00052
SST
R00054
SST
R15899
SST SA±76
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2076 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(d) Using SST and a press, install the companion flange.
SST 09223±46011, 09325±40010
9. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Adjust the drive pinion preload by tightening the compan-
ion flange nut.
HINT:
Using SST to hold the flange, tighten the nut.
SST 09229±55010, 09330±00021
NOTICE:
As there is no spacer, tighten the nut a little at a time, being
careful not to overtighten it.
(b) Using SST and a torque wrench, measure the preload.
SST 09229±55010
Preload (at starting):
New bearing:
1.5 ± 1.8 N´m (15 ± 18 kgf´cm, 13.0 ± 15.6 in.´lbf)
Reused bearing:
0.5 ± 0.8 N´m (5 ± 8 kgf´cm, 4.3 ± 6.9 in.´lbf)
HINT:
For vehicles which have run 8,000 km (5,000 miles) or less, if
the preload value measured before disassembly is greater than
the specification for a reused bearing, return the preload to the
same as before disassembly.
10. INSTALL SIDE BEARING OUTER RACES AND AD-
JUSTING PLATE WASHERS
Using SST and a press, install the 2 adjusting plate washers
and outer races.
SST 09950±60020 (09951±00810),
09950±70010 (09951±07150)

R00022
R15900
SST RH
Front
R00027
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA±77
2077 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
11. INSTALL DIFFERENTIAL CASE IN CARRIER
Install the drive side bearing in the differential carrier first, as
shown in the illustration, then install the differential case.
12. INSTALL DIFFERENTIAL CARRIER RETAINERS
(a) Using SST and a hammer, install 2 carrier retainers.
SST 09950±60020 (09951±00890),
09950±70010 (09951±07150)
(b) Tighten the 16 bolts.
Torque: 22 N´m (225 kgf´cm, 16 ft´lbf)
13. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the backlash of the ring gear at
3 positions at least.
Backlash: 0.08 ± 0.13 mm (0.0031 ± 0.0051 in.)
NOTICE:
The difference between the maximum and minimum mea-
sure values must be less than 0.05 mm (0.0020 in.).
HINT:
The measured values should be used as reference when se-
lecting washers, so take a note of the values.

R00054
SST SA±78
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2078 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
If the backlash is not within the specification replace the washer
on the ring gear side with one of a different thickness using the
following procedure.
Adjusting washer thickness
No. Thickness mm (in.)No. Thickness mm (in.)No. Thickness mm (in.)
02 2.02 (0.0795)32 2.32 (0.0913)62 2.62 (0.1031)
04 2.04 (0.0803)34 2.34 (0.0921)64 2.64 (0.1039)
06 2.06 (0.0811)36 2.36 (0.0929)66 2.66 (0.1047)
08 2.08 (0.0819)38 2.38 (0.0937)68 2.68 (0.1055)
10 2.10 (0.0827)40 2.40 (0.0945)70 2.70 (0.1063)
12 2.12 (0.0835)42 2.42 (0.0953)72 2.72 (0.1071)
14 2.14 (0.0843)44 2.44 (0.0961)74 2.74 (0.1079)
16 2.16 (0.0850)46 2.46 (0.0969)76 2.76 (0.1087)
18 2.18 (0.0858)48 2.48 (0.0976)78 2.78 (0.1094)
20 2.20 (0.0866)50 2.50 (0.0984)80 2.80 (0.1102)
22 2.22 (0.0874)52 2.52 (0.0992)82 2.82 (0.1100)
24 2.24 (0.0882)54 2.54 (0.1000)84 2.84 (0.1118)
26 2.26 (0.0890)56 2.56 (0.1008)86 2.86 (0.1126)
28 2.28 (0.0898)58 2.58 (0.1016)±
30 2.30 (0.0906)60 2.60 (0.1024)±
14. MEASURE TOTAL PRELOAD
Using SST and a torque wrench, measure the preload with the
teeth of the drive pinion and ring gear in contact.
SST 09229±55010
Total preload (at starting):
Drive pinion preload plus
0.5 ± 0.8 N´m (5 ± 8 kgf´cm, 4.3 ± 6.9 in.´lbf)
If the measured preload is less than the specification, replace
the washer of the ring gear's tooth surface side with a thicker
one.
If the preload is greater than the specification, replace the
washer of the ring gear's tooth surface side with a thinner one.
HINT:
Changing the snap ring thickness by 0.02 mm (0.0008 in.) will
change the total preload by approx. 0.1 N´m (1 kgf´cm, 0.9
in.´lbf).

R00020
SA1125
Proper Contact Pattern
Forward Reverse
SA1195
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA±79
2079 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
15. INSPECT TOOTH CONTACT PATTERN
(a) Coat 3 or 4 teeth at the 3 different positions on the ring
gear with red lead.
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.
If tooth contact pattern is not correct, replace the adjusting
washer installed on the front of the drive pinion rear bearing to
adjust it.
NOTICE:
Make sure to always use a new one when replacing adjust-
ing washer.
HINT:
Refer to the table on the next page for selection of the adjusting
washer.

V02917
Tooth contact pattern
ForwardReverse
+ 0.08 mm
(+ 0.0031 in.)
+ 0.14 mm
(+ 0.0055 in.)Adjusting washer selection
Replacing the washer with one
0.08 mm (0.0031 in.) thicker will
give proper contact pattern.
± 0.08 mm
(± 0.0031 in.)
± 0.14 mm
(± 0.0055 in.)Replacing the washer with one
0.14 mm (0.0055 in.) thicker will
give proper contact pattern.
Replacing the washer with one
0.08 mm (0.0031 in.) thicker
will give proper contact pattern.
Replacing the washer with one
0.14 mm (0.0055 in.) thicker will
give proper contact pattern. SA±80
± SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2080 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
HINT:
Adjust washers in 42 (different thickness in 0.01 mm (0.004 in.))
units are available.
No. Thickness mm (in.)No. Thickness mm (in.)No. Thickness mm (in.)
87 1.87 (0.0736)01 2.01 (0.0791)15 2.15 (0.0846)
88 1.88 (0.0740)02 2.02 (0.0795)16 2.16 (0.0850)
89 1.89 (0.0744)03 2.03 (0.0799)17 2.17 (0.0854)
90 1.90 (0.0748)04 2.04 (0.0803)18 2.18 (0.0858)
91 1.91 (0.0752)05 2.05 (0.0807)19 2.19 (0.0862)
92 1.92 (0.0756)06 2.06 (0.0811)20 2.20 (0.0866)
93 1.93 (0.0760)07 2.07 (0.0815)21 2.21 (0.0870)
94 1.94 (0.0764)08 2.08 (0.0819)22 2.22 (0.0874)
95 1.95 (0.0768)09 2.09 (0.0823)23 2.23 (0.0878)
96 1.96 (0.0772)10 2.10 (0.0827)24 2.24 (0.0882)
97 1.97 (0.0776)11 2.11 (0.0831)25 2.25 (0.0886)
98 1.98 (0.0780)12 2.12 (0.0835)26 2.26 (0.0890)
99 1.99 (0.0783)13 2.13 (0.0839)27 2.27 (0.0894)
00 2.00 (0.0787)14 2.14 (0.0843)28 2.28 (0.0898)
16. REMOVE DIFFERENTIAL CARRIER RETAINERS
(See page SA±67)
17. REMOVE DIFFERENTIAL CASE (See page SA±67)
18. REMOVE DRIVE PINION (See page SA±67)
19. INSTALL SPACER ON DRIVE PINION
Install a new spacer on the drive pinion.
20. INSTALL DRIVE PINION AND FRONT BEARING
(See step 8)
21. INSTALL OIL SLINGER (See step 8)