Axle LEXUS SC400 1991 Service Repair Manual

TORQUE SPECIFICATIONS
BR03B±0G\
 
\

\
Part tightened
 

N
Vm
 

kgf
Vcm
 

ft
Vlbf
\
 \
Master cylinder x Piston stopper bolts 10 100 7
\
 \
Master cylinder x Reservoir 1.7 17.5 15.2 in. Vlbf
\
 
\

\
Master cylinder x Brake booster 

13 

130 

9
\
 \
Brake tube union nut 15 155 11
\
 \
Brake booster clevis lock nut 25 260 19
\
 \
Brake booster x Pedal bracket 15 150 11\
 
\

\
Bleeder plug (TRAC actuator and TRAC accumulator)
 

8.3
 

85
 

74 in.
Vlbf
\
 \
Bleeder plug 11 11 0 8
\
 \
Front disc brake torque plate x Steering knuckle 11 8 1,200 87
\
 \
Front disc brake cylinder installation bolt 34 350 25\
 
\

\
Front disc brake cylinder x Flexible hose bolt
 

30
 

310
 

22
\
 \
Rear disc brake torque plate x Axle carrier 104 1,065 77
\
 \
Rear disc brake cylinder installation bolt 34 350 25
\
 
\

\
Rear disc brake x Flexible hose union bolt 

30 

310 

22
\
 \
Parking brake lever x Floor 59 600 43
\
 \
Parking brake cable No.1 x Floor 9 80 69 in.
Vlbf
\
 \
Parking brake cable retainer x Floor 5.4 55 48 in. Vlbf\
 
\

\
Parking brake cable clamp x Floor
 

19
 

190
 

14
\
 \
ABS actuator x Actuator bracket 5.4 55 48 in.
Vlbf
\
 \
ABS actuator bracket x Body 19 195 14
\
 
\

\
Front speed sensor installation bolt 

7.8 

80 

69 in.
Vlbf
\
 \
Rear speed sensor installation bolt 7.8 80 69 in. Vlbf
\
 \
TRAC pump bracket x Body 19 195 14
\
 \
TRAC pump or accumulator x Union bolt 46 465 34
BR±230±
BRAKE SYSTEM SERVICE SPECIFICATIONS
WhereEverybodyKnowsYourName

3. MEASURE DISC RUNOUTUsing a dial indicator, measure the disc runout at a position
10 mm (0.39 in.) from the outside edge.
Maximum disc runout:
0.05 mm (0.0020 in.)
If the disc's runout is at the maximum value or greater, check
the bearing play in the axial direction and check the axle hub
runout (See page SA±30). If the bearing play and axle hub
runout are not abnormal, adjust the disc runout.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the 2 bolts and torque plate from the knuckle.
(b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and
torque the hub nuts.
Torque: 103 N Vm (1,050 kgf Vcm, 76 ft Vlbf)
Remeasure the disc runout. Make a not of the runout and
disc's position on the hub.
(c) Repeat (b) until the disc has been install on the 3 remaining hub position.
(d) If the minimum runout recorded in (b) and (c) is less than 0.05
mm (0.0020 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater than
0.05 mm (0.0020 in.), replace the disc and repeat step 3.
(f) Install the torque plate and torque the 2 bolts.
Torque: 118 N Vm (1,200 kgf Vcm, 87 ft Vlbf)
CALIPER ASSEMBLY
BR045±0B
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
PARTS INDICATED WITH ARROWS
BR±34
±
BRAKE SYSTEM FRONT BRAKE (SC400)
WhereEverybodyKnowsYourName

(b) Using a screwdriver and hammer, tap out the 2 dust boots.
REAR BRAKE COMPONENTS
INSPECTION AND REPAIR
BR04B±06
1. MEASURE PAD LINING THICKNESSUsing a ruler, measure the pad lining thickness.
Standard thickness:
10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum
thickness or less, or if the pad has severely uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness:
16.0 mm (0.630 in.)
Minimum thickness:
15.0 mm (0.591 in.)
Replace the disc if the thickness of the disc is at the minimum
thickness or less. Replace the disc or grind it on a lathe if it
is scored or is worn unevenly.
3. MEASURE DISC RUNOUT
Measure the disc runout at 10 mm (0.39 in.) from the outer
edge of the disc.
Maximum disc runout:
0.05 mm (0.0020 in.)
If the disc's runout is at the maximum value or greater, check
the bearing play in the axial direction and check the axle hub
runout (See page SA±52). If the bearing play and axle hub
runout are not abnormal, adjust the disc runout.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the 2 bolt and torque plate from the carrier.
(b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of
a turn round from its original position on the hub. Install and
torque the hub nuts.
Torque: 103 N Vm (1,050 kgf Vcm, 76 ft Vlbf)
Remeasure the disc runout. Make a note of the runout and
the disc's position on the hub.
±
BRAKE SYSTEM REAR BRAKE (Disc Brake)BR±41
WhereEverybodyKnowsYourName

REAR BRAKE
(Parking Brake)
COMPONENTS
BR04E±06
PARKING BRAKE DISASSEMBLY
BR04F±09
1. REMOVE REAR WHEEL
2. REMOVE REAR DISC BRAKE ASSEMBLY
(a) Remove the 2 mounting bolts and remove the disc brakeassembly.
(b) Suspend the disc brake so the hose is not stretched.
3. REMOVE DISC
(a) Place matchmarks on the disc and rear axle hub.
(b) Remove the disc. HINT: If the disc can not be removed easily, return the shoe
adjuster until the wheel turns freely.
BR±44
±
BRAKE SYSTEM REAR BRAKE (Parking Brake)
WhereEverybodyKnowsYourName

OKNG
3Check sensor rotor and sensor installation.
C
OK
P
C
OK
C
OK
P
C
OK
Remove front speed sensor rotor (See page BR±71).
Check sensor rotor serrations.
No scratches or missing teeth.
Check the front speed sensor installation.
The installation bolt is tightened properly.
Remove the drive shaft (See page SA±64).
Check the sensor rotor serrations.
No scratches or missing teeth.
Check the rear speed sensor installation.
The installation bolt is tightened properly and there
is no clearance between the sensor and rear axle
carrier.
Replace speed sensor or rotor.
Check and replace ABS (& TRAC) ECU.
±
BRAKE SYSTEM ANTI±LOCK BRAKE SYSTEM (ABS)BR±121
WhereEverybodyKnowsYourName

Shift Lock ECU
Tilt and Power
Telescopic ECU
Airbag ECU
Cruise Control ECU Engine ECUABS and Traction ECU
(w/ Traction System) or
ABS ECU
(w/o Traction System)
Theft Deterrent and
Door Lock ECU
(w/ Traction System)
Traction ECU
Remote Control Mirror ECU A/C Control Amplifier
PPS ECU
Engine Cooling Fan ECU
Component to be aligned
Section of repair manual
for relevant model year
Front Wheels Suspension and Axle (SA) section
Rear Wheels Suspension and Axle (SA) section
Propeller Shaft Propeller Shaft (PR) section
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always \
follow the directions and
notes given in section BR of the repair manual for the relevant model ye\
ar when handling brake sys-
tem parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed t\
he air out of the TRAC
system.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in \
the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. P\
articularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Alway\
s follow the directionsgiven in the repair manual for the relevant model year during alignment \
and section DI of this manual.
4. ECU (ELECTRONIC CONTROL UNIT)
Locations of ECUs
INTRODUCTIONIN-8
WhereEverybodyKnowsYourName

ASSEMBLY REMOVAL AND
INSTALLATION
COMPONENTS
SA09A±07
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±81
WhereEverybodyKnowsYourName

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

(e) Remove the upper mount stopper from the differential carrier.
HINT:
w Same vehicles have the adjusting shim for adjusting the
propeller shaft joint angle installed on top of the upper
mount stopper.
w Adjusting shim is not always as it is used upon need.
DIFFERENTIAL INSTALLATION
SA0S7±06
1. INSTALL DIFFERENTIAL
(a) Install the upper mount stopper on the differential carrier.
HINT:
wUse the upper mount stopper which was removed.
w On vehicles with the adjusting shim installed on top of
the mount upper stopper, install that adjusting shim.
w Adjusting shim is not always as it is used upon need.
(b) Support the differential with a jack and install the lower stoppers and 2 new bolts.
Torque: 147 N Vm (1,500 kgf Vcm, 108 ft Vlbf)
(c) Using a hexagon wrench, install 2 new LH mounting bolts.
Torque: 142 N Vm (1,450 kgf Vcm, 105 ft Vlbf)
(d) Using a hexagon wrench, install a new RH mounting bolt.
Torque: 142 N Vm (1,450 kgf Vcm, 105 ft Vlbf)
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±83
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