ect LEXUS SC300 1991 Service Repair Manual

DIFFERENTIAL REMOVAL
SA0S6±05
1. REMOVE PROPELLER SHAFT(See page PR±6 or 24)
2. DRAIN DIFFERENTIAL OIL
3. DISCONNECT REAR DRIVE SHAFTS
(a) Place matchmarks on the drive shafts and side gear shafts.
(b) Using a hexagon wrench, disconnect the drive shafts from
the differential.
(c) Hang up the drive shafts using wire, etc.
4. REMOVE DIFFERENTIAL
(a) Support the differential with a jack.
(b) Using a hexagon wrench, remove the 3 bolts.
(c) Remove the 2 bolts and lower stoppers.
(d) Remove the differential.
SA±82
±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

2. CONNECT REAR DRIVE SHAFTS
(a) Align the matchmarks on the side gear shaft and drive shafts.
(b) Apply a light coat of engine oil on the threads of the bolts.
(c) Temporarily install the 12 hexagon bolts and 4 washers.
(d) Using a hexagon wrench, torque the bolts.
Torque: 83 N Vm (850 kgf Vcm, 61 ft Vlbf)
3. INSTALL PROPELLER SHAFT
(See page PR±12 or 28)
4. FILL DIFFERENTIAL WITH OIL
Oil grade: API GL±5 Hypoid Gear Oil
Viscosity: Above±18
C (0
F) SAE 90
Below±18
C (0
F) SAE 80W±90 or 80W
Capacity:
1.35 liters (1.42 US qts, 1.19 lmp qts)
SA±84±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

DIFFERENTIAL CARRIER INSPECTION
SA0V3±05
1. CHECK RUNOUT OF DRIVE PINION SHAFTMeasure the runout of the drive pinion shaft at a position pin-
ion 10 mm (0.39 in.) from the end of the shaft.
Maximum runout:
0.08 mm (0.0031 in.)
If the runout is greater than the maximum, replace the drive
pinion and ring gear.
2. REMOVE DIFFERENTIAL CARRIER COVER
(a) Remove the 8 bolts from the carrier cover.
(b) Using a brass bar and hammer, separate the cover and carrier.
3. CHECK RING GEAR RUNOUT
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than the maximum, replace the drive
pinion, ring gear and differential case.
4. CHECK RING GEAR BACKLASH Measure the backlash of the ring gear at 3 points at least and
check that the average value is within the specification.
Backlash (average value):
0.08±0.13 mm (0.0031±0.0051 in.)
NOTICE: The difference between the maximum and minimum
measured values must be less than 0.05 mm (0.0020 in.).
SA±86±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

If the backlash is not within the specification, adjust the back-
lash. (See page SA±98)
5. MEASURE DRIVE PINION PRELOAD Using SST and a torque wrench, measure the drive pinion
preload using the backlash of the drive pinion and ring gear.
Preload (at start):
0.5±0.8 N Vm (5±8 kgf Vcm, 4.3±6.9 in. Vlbf)
HINT: With vehicles which have run less than 8,000 km
(5,000 miles), the preload may be large.
SST 09229±55010
Maximum preload (at start):
1.8 N Vm (18 kgf Vcm, 16.0 in. Vlbf)
6. CHECK TOTAL PRELOAD
Using SST and a torque wrench, measure the total preload.
SST 09229±55010
Total preload (at start):
In addition to drive pinion preload
0.5±0.8 N Vm (5±8 kgf Vcm, 4.3±6.9 in. Vlbf)
If necessary, disassemble and inspect the differential.
7. CHECK PINION GEAR BACKLASH Measure the pinion gear backlash while holding one side
gear toward the case.
Backlash:
0.05±0.02 mm (0.0020±0.0079 in.)
If the backlash is not within the specification, install the cor-
rect thrust washer. (See page SA±93)
8. CHECK TOOTH CONTACT PATTERN (See page SA±99)
DIFFERENTIAL CARRIER DISASSEMBLY
SA0V4±02
HINT: When fastening the differential carrier to an overhaul
stand, etc., fasten it at the 4 places on the ring gear side
shown in the illustration.
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±87
WhereEverybodyKnowsYourName

(b) Remove following parts from the differential case.wPinion shaft
w 2 differential pinions
w 2 pinion thrust washers
w 2 side gears
w 2 side gears thrust washers
DUST DEFLECTOR AND DUST COVER
REPLACEMENT
SA0V5±01
1. REPLACE COMPANION FLANGE DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector.
SST 09608±35014 (09608±06090), 09950±00020
(b) Using SST and a press, install a new dust deflector. SST 09316±60010 (09316±00010)
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, 09608±35014 (09608±06020,09608±06120)
SA±92
±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

HINT: If the dust cover does not fit tightly against the flange
of the side gear shaft, use a screwdriver to drive it down tight.
DIFFERENTIAL CARRIER ASSEMBLY
SA0V6±04
1. ADJUST DIFFERENTIAL PINION GEAR BACKLASH
(a) Install the proper thrust washers on the side gears.HINT: Using the table below, select thrust washers which will
ensure that the backlash is within specification.
Thrust washer thickness:
 Thickness mm (in.) Thickness mm (in.) 

1.6 (0.063)1.8 (0.071)
 1.7 (0.067)±
(b) Install the side gears, pinion gears, pinion gear thrust
washers and pinion shaft in the differential case.
HINT: Align the holes of the dif ferential case and pinion shaft.
(c) Push the side gear shafts gently into the differential case by hand and install them.
(d) Measure the pinion gear backlash while holding one side gear toward the case.
Backlash:
0.05±0.20 mm (0.0020±0.0079 in.)
If the backlash is not within the specification, install the side
gear thrust washers with different thicknesses.
(e) Remove the side gear shaft.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Using a hammer and punch, install the straight pin through the differential case and hole of the pinion shaft.
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±93
WhereEverybodyKnowsYourName

(b) Tighten the 8 bolts.
Torque: 22 NVm (225 kgf Vcm, 16 ft Vlbf)
14. CHECK RING GEAR BACKLASH
Using dial gauge, measure the backlash of the ring gear at
3 positions at least.
Backlash (average value):
0.08±0.13 mm (0.0031±0.0051 in.)
NOTICE: The difference between the maximum and minimum
measured values must be less than 0.05 mm (0.0020 in.)
HINT: The measured values should be used for reference
when selecting washers, so make a memo of the values.
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: mm (in.)
 No. Thickness No. Thickness No. Thickness 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)
182.18 (0.0858)482.48 (0.0976)782.78 (0.1094) 20 2.20 (0.0866) 50 2.50 (0.0984) 80 2.80 (0.1102) 22 2.22 (0.0974) 52 2.52 (0.0992) 82 2.82 (0.1110) 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)  
15. MEASURE TOTAL PRELOAD
Using SST and a torque wrench, measure the total preload.
SST 09229±55010
Total preload
In addition to drive pinion preload
0.5±0.8 N Vm (5±8 kgf Vcm, 4.3±6.9 in. Vlbf)
SA±98±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

If the measure preload is less than 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 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 Vm (1 kgf Vcm,
0.9 in. Vlbf)
16. INSPECT TOOTH CONTACT PATTERN
(a) Coat 3 or 4 teeth at three different position 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: Be sure to always use a new part when replacing ad-
justing washer.
HINT: Refer to the table below for selection of the adjusting
washer.
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±99
WhereEverybodyKnowsYourName

DIFFERENTIAL MOUNTING CUSHION
DIFFERENTIAL MOUNT CUSHION
REPLACEMENT
SA0V7±03
1. REMOVE DIFFERENTIAL(See page SA±82)
2. REMOVE DIFFERENTIAL MOUNT CUSHION Using SST, remove the differential mount cushion.
SST 09316±12010, 09570±24010
NOTICE:
w When driving out the mount cushion, be careful not to
touch the member with the SST.
w Align the SST straight so that the bolt of the SST parallels
the center line of the mount cushion.
w When installing the bolts to the LH and RH differential
mount cushions, make sure the bolts are passed through
the correct holes in the SST, as shown in the illustration.
3. INSTALL DIFFERENTIAL MOUNT CUSHION Using SST, install the cushion so that the marks are posi-
tioned, as shown in the illustration.
SST 09570±24010
NOTICE:
wDo not make a mistake with left and right sides or top
and bottom.
w Set the SST after temporarily installing the differential
mount cushion into the member so as not to be installed
at an angle.
w To confirm that the differential mount cushion is aligned
straight in relation to the member, check that the SST is
fully in contact with all of the cushion.
4. INSTALL DIFFERENTIAL (See page SA±83)
SA±104
±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

REAR SHOCK ABSORBER INSPECTION
SA0SD±03
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual operation
sounds.
If there is any abnormality, replace the shock absorber with
a new one.
NOTICE: When discarding the shock absorber, use the
following procedure.
REAR SHOCK ABSORBER DISPOSAL
SA0SE±03
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDERUsing a drill, make a hole in the cylinder, as shown to remove
the gas inside.
CAUTION: The gas coming out is harmless, but be care-
ful of chips which may fly up when drilling.
REAR SHOCK ABSORBER
INSTALLATION
SA0WB±02
1. INSTALL SUSPENSION SUPPORT AND COIL SPRING
(a) Install the spring bumper to the suspension support.
(b) Install the insulator to the suspension support. HINT: Match the bolt of the suspension support with the cut±
off part of the insulator.
(c) Using SST, compress the coil spring. SST 09727±30020
NOTICE: Do not use an impact wrench.
It will damage the SST.
SA±110
±
SUSPENSION AND AXLE REAR SUSPENSION
WhereEverybodyKnowsYourName