Lexus RX300 (MCU15). Service manual - part 557

SA198–02

R04465

SST

R02524

Steel Plate

SA–68

–

SUSPENSION AND AXLE

REAR DIFFERENTIAL CARRIER

LEXUS RX300   (RM785E)

REPLACEMENT

1.

REPLACE COMPANION FLANGE DUST DEFLECTOR,
IF NECESSARY

(a)

Using SST and a press, remove the dust deflector.
SST

09950–00020

(b)

Using a press, install a new dust deflector.

2.

REPLACE SIDE GEAR SHAFT DUST COVER, IF NEC-
ESSARY

(a)

Using a screwdriver and hammer, remove the side gear
shaft dust cover.

(b)

Using a steel plate and press, install a new dust cover to
the side gear shaft.

NOTICE:
Be careful not to damage the dust cover.

FA1121

SA21K–01

FA1123

FA1124

SA1143

Boiling Water

–

SUSPENSION AND AXLE

REAR DIFFERENTIAL CARRIER

SA–69

LEXUS RX300   (RM785E)

REASSEMBLY

1.

REASSEMBLE DIFFERENTIAL CASE

(a)

Install the 2 thrust washers on the 2 side gears.

(b)

Install the 2 side gears, 2 pinion gears, 2 pinion gear
thrust washers and pinion shaft in the differential case.

HINT:
Align the holes of the differential case and pinion shaft.

(c)

Measure the side gear backlash while holding 1 pinion
gear toward the differential case.
Backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.)

If the backlash is not within the specification, install the 2 side
gear thrust washers with different thicknesses.
HINT:
Refer to the following table to select 2 thrust washers which will
ensure that the backlash is within the specification.

Thrust washer thickness

Thickness     mm (in.)

Thickness     mm (in.)

0.93 – 0.97 (0.0366 – 0.0382)

1.18 – 1.22 (0.0465 – 0.0480)

0.98 – 1.02 (0.0386 – 0.0402)

1.23 – 1.27 (0.0484 – 0.0500)

1.03 – 1.07 (0.0406 – 0.0421)

1.28 – 1.32 (0.0504 – 0.0520)

1.08 – 1.12 (0.0425 – 0.0441)

1.33 – 1.37 (0.0524 – 0.0539)

1.13 – 1.17 (0.0445 – 0.0461)

1.38 – 1.42 (0.0543 – 0.0559)

(d)

Using a pin punch and hammer, install the straight pin
through the differential case and hole of the pinion shaft.

(e)

Using a chisel and hammer, stake the outside of the differ-
ential case pin hole.

2.

INSTALL RING GEAR ON DIFFERENTIAL CASE

(a)

Clean the contact surfaces of the differential case and
ring gear.

(b)

Heat the ring gear to approx. 100 °C (212 °F) in the boiling
water.

(c)

Carefully take the ring gear out of the boiling water.

(d)

After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.

F03758

Matchmarks

F03759

SST

F03760

SA–70

–

SUSPENSION AND AXLE

REAR DIFFERENTIAL CARRIER

LEXUS RX300   (RM785E)

(e)

Align the matchmarks on the ring gear and differential
case.

(f)

Temporarily install the 4 new lock plates and 8 bolts.

(g)

After the ring gear cools down enough, torque the 8 bolts
uniformly at a time.
Torque: 97 N·m (985 kgf·cm, 71 ft·lbf)

(h)

Using a chisel and hammer, stake the 4 lock plates.

HINT:
Stake one claw so that it is flush with the flat surface of the bolt.
For the claw contacting the protruding portion of the bolt, stake
only the half on the tightening side.

3.

INSTALL SIDE BEARINGS

Using SST and a press, install the 2 side bearings into the differ-
ential case.

SST

09710–22021 (09710–01031)

4.

INSPECT RING GEAR RUNOUT

(a)

Install the differential case on the carrier, and install the
2 plate washers so that there is no play in the bearing.

(b)

Install the bearing caps.

(c)

Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 in.)

(d)

Remove the 2 bearing caps, 2 plate washers and differen-
tial carrier.

W01226

SST

SST

Front

Rear

SA3102

SST

F01250

R11163

SST

–

SUSPENSION AND AXLE

REAR DIFFERENTIAL CARRIER

SA–71

LEXUS RX300   (RM785E)

5.

INSTALL FRONT AND REAR BEARING OUTER
RACES

(a)

Front side:
Using SST and a press, install the outer race to the carrier.
SST

09950–60020  (09951–00790),
09950–70010 (09951–07150)

(b)

Rear side:
Using SST and a press, install the outer race to the carrier.
SST

09950–60020  (09951–00710),
09950–70010 (09951–07150)

6.

INSTALL DRIVE PINION REAR BEARING

(a)

Install the removed plate washer on the drive pinion.

(b)

Using SST and a press, install the rear bearing onto the
drive pinion.
SST

09506–30012

7.

TEMPORARILY ADJUST DRIVE PINION PRELOAD

(a)

Install the drive pinion and front bearing.

HINT:
Assemble the spacer, oil slinger and oil seal after adjusting the
gear contact pattern.

(b)

Using SST, install the companion flange.
SST

09950–30011 (09951–03010, 09953–03010,
09954–03010,  09955–03030, 09956–03020)

(c)

Coat the threads of the nut with MP grease.