Lexus ES300 (1997 year). Manual - part 91

AUTOMATIC TRANSAXLE

DIFFERENTIAL ASSEMBLY

-

AX-91

DIFFERENTIAL CASE DISASSEMBLY

1.

REMOVE SIDE BEARING
Using SST, remove the 2 side bearings.
SST 09608-1601 1, 09550-40010

2.

REMOVE RING GEAR

(a)

Place matchmarks on both the differential case and ring
gear.

(b)

Remove the 12 bolts.

(c)

Using a plastic hammer, tap out the ring gear.

3.

CHECK SIDE GEAR BACKLASH
Using a dial gauge, measure the backlash of each side
gear while holding one pinion toward the case.

Standard backlash:

0.05 - 0.20 mm (0.0020 - 0.0079 in.)

AX0TZ-02

AUTOMATIC TRANSAXLE

DIFFERENTIAL ASSEMBLY

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AX-92

4.

DISASSEMBLE DIFFERENTIAL CASE

(a)

Drive out the pinion shaft lock pin from the side on which
the ring gear is installed.

(b)

Remove the pinion shaft from the case.

(c)

Remove the 2 pinions and side gears with the 4 thrust
washers.

DIFFERENTIAL CASE ASSEMBLY

1.

ASSEMBLE DIFFERENTIAL CASE

(a)

Install the removed thrust washers to the side gears.

(b)

Install the side gears with thrust washers, pinion thrust
washers and pinion gears.

(c)

Install the pinion shaft.

AX0U0-02

AUTOMATIC TRANSAXLE

DIFFERENTIAL ASSEMBLY

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AX-93

(d)

Check the side gear backlash.
Measure the side gear backlash while holding one pinion
gear toward the case.

Standard backlash:

0.05-0.20 mm (0.0020-0.0079 in.)

Refering to the table below, select thrust washers which
will ensure that the backlash is within specification. Try to
select washers of the same size for both sides.

Thrust washer thickness

mm (in.)

Thickness mm (in.)

Thickness mm (in.)

1.60 (0.0630)

1.70 (0.0670)

1.80 (0.0709)

If the backlash is not within specification, install a thrust
washer of a different thickness.

(e)

Using a pin punch and hammer, drive the lock pin through
the case and hole in the pinion shaft.

(f)

Stake the differential case.

2.

INSTALL RING GEAR

(a)

Clean the contact surface of the differential case.

(b)

Heat the ring gear to about 100

°

C (212

°

F) in an oil bath.

NOTICE: Do not heat the ring gear above 110

°

C (230

°

F).

(c)

Carefully remove the ring gear from the oil bath.

(d)

Clean the contact surface of the ring gear with cleaning
solvent.

(e)

Quickly install the ring gear on the differential case.
Install the 12 bolts.
HINT: Align the matchmarks on the differential left case
and contact the ring gear.

(f)

Tighten the set bolts uniformly a little at a time.
Torque the bolts.

Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)

AUTOMATIC TRANSAXLE

DIFFERENTIAL ASSEMBLY

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AX-94

3.

INSTALL SIDE BEARING

(a)

Install the speedometer drive gear onto the differential
case.

(b)

Using SST and a press, press in the RH side bearing onto
the differential case.
SST  09316-20011

(c)

Using SST and a press, press in the LH side bearing onto
the differential case.
SST 09316-60010 (09316-00010)