1991 LEXUS SC300 differential

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.
SA±88
±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

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.
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±89
WhereEverybodyKnowsYourName

(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.
SA±90
±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

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.
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±91
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) 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.
SA±94±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

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
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±95
WhereEverybodyKnowsYourName