LEXUS SC400 1991 Service Repair Manual

1. REMOVE SIDE GEAR SHAFTUsing SST, remove the side gear shaft.
SST 09520±24010
NOTICE: Be careful not to damage the oil seal.
2. REMOVE SIDE GEAR SHAFT OIL SEALSUsing SST, remove the oil seals.
SST 09308±00010
3. REMOVE DIFFERENTIAL CARRIER RETAINER
(a) Remove the 8 bolts.
(b) Using SST, remove the carrier retainer. SST 09950±20017
4. REMOVE DIFFERENTIAL CASE Take the differential case out of the carrier while lifting the ring
gear side, as shown in the illustration.
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5. REMOVE O±RING FROM DIFFERENTIAL CARRIERRETAINER
Using a screwdriver, remove the O±ring.
6. REMOVE SIDE BEARING OUTER RACE AND PLATE WASHER
Using SST and a press, press out the outer races and wash-
ers.
SST 09608±35014 (09608±06020, 09608±06110)
7. REMOVE DRIVE PINION, SPACER AND COMPANION FLANGE
(a) Using a hammer and chisel, loosen the staked part of the nut.
(b) Using SST, remove the nut. SST 09229±55010, 09330±00021
(c) Using a press, remove the drive pinion with the rear bearing and remove the companion flange.
NOTICE: Be careful not to drop the drive pinion.
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(d) Remove the spacer from the drive pinion.
8. REMOVE OIL SEALUsing SST, remove the oil seal.
SST 09308±00010
9. REMOVE OIL SLINGER AND FRONT BEARING
10. REMOVE REAR BEARING FROM DRIVE PINION Using SST and a press, remove the rear bearing from the
drive pinion.
SST 09950±00020
11. REMOVE FRONT AND REAR BEARING OUTER RACES AND ADJUSTING WASHER
NOTICE: Do not remove the outer race except when replacing
the bearings.
Using a brass bar and hammer, drive out the outer races and
adjusting washer from the differential carrier.
HINT: Measure the adjusting washer and note the thickness
for reassembly.
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12. REMOVE LH AND RH SNAP RING FROM SIDE GEARSHAFT
Using a screwdriver, remove the snap rings from the side
gear shaft.
13. REMOVE SIDE BEARINGS Using SST, r emove the side bearings LH and RH from the dif-
ferential case.
SST 09950±20017
14. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 10 ring gear set bolts.
(c) Using a plastic hammer, tap on the ring gear to separate it from the differential case.
15. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a hammer and punch, drive out the straight pin.
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(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)
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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.
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(b) Stake the differential case.
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and thethreads of the ring gear and differential case.
(b) Heat the ring gear in boiling water.
(c) A f t e r t h e m o i s t u r e o n t h e r i n g g e a r h a s c o m p l e t e l y evaporated, quickly install the ring gear to the differential
case.
HINT: Align the matchmarks on the ring gear and the dif feren-
tial case.
(d) 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 10 new ringgear set bolts to which thread lock has been applied.
Thread lock:
Part No. 08833±00100, THREE BOND 1360 K or
equivalent.
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 Vm (650 kgf Vcm, 47 ft Vlbf)
(c) Tighten the bolts an additional 60±90
.
NOTICE: Tighten the bolts in diagonally opposite pairs.
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5. INSTALL SIDE BEARINGSUsing SST and a press, install the side bearings.
SST 09550±10012 (09252±10010, 09558±10010)09710±30050
6. INSTALL DRIVE PINION BEARING OUTER RACES AND ADJUSTING WASHER
HINT: The adjusting washer is used for adjusting the tooth
contact pattern. 42 types of washer with differential thick-
nesses 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 thickness
if necessary.
When removing an adjusting washer, be sure to replace it
with a new one.
(a) Using SST and a press, install a new adjusting washer and the front bearing outer race.
SST 09250±10011 (09252±10010, 09255±10011)
(b) Using SST and a press, install the rear bearing outer race. SST 09608±30012 (09608±04020, 09608±04100)
7. INSTALL REAR BEARING TO DRIVE PINION Using SST and a press, install the rear bearing.
SST 09502±24010
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8. INSTALL DRIVE PINION AND FRONT BEARING
(a) Install the drive pinion in the differential carrier.
(b) Using SST and a press, install the front bearing on the drivepinion.
SST 09316±60010 (09316±00010), 09608±30012
(09608±04030)
HINT: Assemble the spacer and oil seal after adjusting the
tooth contact pattern.
9. INSTALL OIL SLINGER AND COMPANION FLANGE
(a) Install the oil slinger.
(b) Using SST and a press, install the companion flange. SST 09223±63010, 09325±40010
10. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Adjust the drive pinion preload by tightening the companion 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 drive pinion preload.
SST 09229±55010
Preload (at start):
New bearing:
1.2±1.8 N Vm (12.4±18.4 kgf Vcm, 10.8±16.0 in. Vlbf)
Reused bearing
0.5±0.8 N Vm (5±8 kgf Vcm, 4.3±6.9 in. Vlbf)
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HINT: For vehicle which have run 8,000 km (5,000 miles) or
less, if the preload value measured disassembly is greater
than the specification for a reused bearing, return the preload
to the same as before disassembly.
11. INSTALL SIDE BEARING OUTER RACE AND ADJUST WASHER
Using SST and a press, press the outer race and washer.
SST 09608±35014 (09608±06020, 09608±06210)
12. 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.
13. INSTALL DIFFERENTIAL CARRIER RETAINERS
(a) Using SST and hammer, install the bearing retainer. SST 09608±35014 (09608±06020, 09608±06180)
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