1991 LEXUS SC300 differential

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)
SA±96±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

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)
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±97
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

HINT: Adjust washer in 42 (different thicknesses in 0.01 mm
(0.004 in.) unit are available.
Adjusting washer thickness: mm (in.)
 No. Thickness No. Thickness No. Thickness No. Thickness
871.87 (0.0736)981.98 (0.0780)092.09 (0.0823)202.20 (0.0866) 89 1.89 (0.0744) 00 2.00 (0.0787) 11 2.11 (0.0831) 22 2.22 (0.0874) 90 1.90 (0.0748) 01 2.01 (0.0791) 12 2.12 (0.0835) 23 2.23 (0.0878) 91 1.91 (0.0752) 02 2.02 (0.0795) 13 2.13 (0.0839) 24 2.24 (0.0882) 92 1.92 (0.0756) 03 2.03 (0.0799) 14 2.14 (0.0843) 25 2.25 (0.0886)
 93 1.93 (0.0760) 04 2.04 (0.0803) 15 2.15 (0.0846) 26 2.26 (0.0890)
 94 1.94 (0.0764) 05 2.05 (0.0807) 16 2.16 (0.0850) 27 2.27 (0.0894)
 95 1.95 (0.0768) 06 2.06 (0.0811) 17 2.17 (0.0854) 28 2.28 (0.0898)
 96 1.96 (0.0772) 07 2.07 (0.0815) 18 2.18 (0.0858)  
 97 1.97 (0.0776) 08 2.08 (0.0819) 19 2.19 (0.0862)  
17. REMOVE DIFFERENTIAL RETAINER(See page SA±88)
18. REMOVE DIFFERENTIAL CASE (See page SA±88)
19. REMOVE DRIVE PINION
(See page SA±89)
SA±100
±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

20. INSTALL SPACER ON DRIVE PINIONInstall a new spacer on the drive pinion.
21. INSTALL DRIVE PINION AND FRONT BEARING (See page SA±96)
22. INSTALL OIL SLINGER (See page SA±96)
23. INSTALL OIL SEAL
(a) Apply the MP grease to a new oil seal lip.
(b) Using SST, install a new oil seal until its end is flash with the surface of the differential carrier.
SST 09316±60010 (09316±00010, 09316±00040)09502±12010
24. INSTALL COMPANION FLANGE Using SST and a press, install the companion flange.
SST 09223±63010, 09325±40010
NOTICE: Be careful not to damage the oil seal.
25. ADJUST DRIVE PINION PRELOAD
(a) Coat the threads and flange of a new nut with hypoid gear oilfor LSD.
(b) Using SST, tighten the nut. SST 09229±55010, 09330±00021
(c) Using SST and a torque wrench, measure the drive pinion preload.
SST 09229±55010
Preload (at starting):
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 (5.10 ± 8.0 kgf Vcm, 4.3 ± 6.9 in. Vlbf)
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±101
WhereEverybodyKnowsYourName

wIf the preload is greater than the specification, replace
the spacer.
w If the preload is less than the specification, retighten the
nut 13 NVm (130 kgfVcm, 9 ftVlbf) at a time until the
specified preload is reached.
Maximum torque:
490 N Vm (5,000 kgf Vcm, 362 ft Vlbf)
If the maximum torque is exceeded while retightening the
nut, replace the spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.
26. CHECK RUNOUT OF DRIVE PINION SHAFT Measure the r unout of the drive pinion shaft at a point 10 mm
(0.39 in.) from the end of the shaft.
Maximum runout:
0.08 mm (0.0031 in.)
27. INSTALL DIFFERENTIAL CASE IN CARRIER(See page SA±97)
28. INSTALL O±RING
(a) Coat a new O±ring with hypoid gear oil.
(b) Install the O±ring to the carrier retainer.
29. INSTALL OIL SEAL
(a) Using SST and a press, install a new oil seal to the carrier retainer.
SST 09608±32010, 09608±35014 (09608±06020)
(b) Coat the MP grease to the oil seal lip.
30. INSTALL SIDE BEARING RETAINER (See page SA±97)
31. RECHECK BACKLASH, TOTAL PRELOAD AND TOOTH CONTACT PATTERN
SA±102
±
SUSPENSION AND AXLE REAR DIFFERENTIAL
WhereEverybodyKnowsYourName

32. STAKE DRIVE PINION NUT
33. INSTALL SNAP RING TO SIDE GEAR SHAFT
(a) Install a new snap ring to the shaft.
(b) Coat the MP grease to the snap ring.
34. INSTALL SIDE GEAR SHAFTSUsing a hammer and brass bar install the side gear shafts.
HINT: Whether or not the side gear shaft is making contact
with the pinion shaft can be known by the sound or feeling
when driving it in.
NOTICE: Be careful not to damage the oil seal.
35. REMOVE DIFFERENTIAL CARRIER FROM OVERHAULSTAND, ETC.
36. INSTALL DIFFERENTIAL CARRIER COVER
(a) Clean the contact surfaces of the carrier and cover of any residual packing material using cleaner.
(b) Coat the seal packing to the carrier or cover.
Seal packing:
Part No. 08826±00110, THREE BOND 1389 or equivalent
NOTICE: After installing the cover, wait at least 1 hour before
filling it with oil or running the vehicle.
(c) Install the carrier cover to the carrier with the 8 bolts.
Torque: 47 N Vm (475 kgf Vcm, 34 ft Vlbf)
(d) Install the breather plug.
Torque: 21 N Vm (210 kgf Vcm, 15 ft Vlbf)
±
SUSPENSION AND AXLE REAR DIFFERENTIALSA±103
WhereEverybodyKnowsYourName