Lexus ES300 (2002 year). Manual - part 408

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AUTOMATIC TRANSMISSION / TRANS

FRONT DIFFERENTIAL ASSY (U150E)

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127

U150E A/T REPAIR MANUAL   (RM913U)

11.

INSPECT BACKLASH

(a)

Using a dial indicator, inspect the backlash of the side
gear.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness

Mark

Thickness

-

1.625 mm (0.0640 in.)

-

1.725 mm (0.0679 in.)

-

1.825 mm (0.0719 in.)

12.

INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN

(a)

Using a pin punch and hammer, install the pinion shaft
straight pin.

(b)

Using a chisel and hammer, stake the differential case.

NOTICE:
Stake it after adjusting the backlash.

13.

INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING

(a)

Using SST and a press, install the front differential case
rear tapered roller bearing to the differential case.
SST

09316- 12010, 09550- 60010 (09951- 00490),
09950-70010  (09951-07100)

C83736

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(b)

Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST

09550- 60010 (09951- 00490), 09950- 60020
(09951-00910)

14.

INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING

(a)

Using SST and a press, install the front differential case
front tapered roller bearing to the differential case.
SST

09316- 12010, 09550- 60010 (09951- 00490),
09950-70010  (09951-07100)

(b)

Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST

09950- 70010 (09951- 07150), 09950- 60020
(09951-00890)

NOTICE:
Clearance is not allowed between the bearing and trans-
axle housing.

15.

ADJUST DIFFERENTIAL SIDE BEARING RRELOAD

(a)

Install the differential assy to the transaxle case.

D26384

C

C

C

C

A

B

D

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FRONT DIFFERENTIAL ASSY (U150E)

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U150E A/T REPAIR MANUAL   (RM913U)

(b)

Clean the matching surfaces of the transaxle case and
transaxle housing.

(c)

Install the transaxle housing to the transaxle case and
tighten them with the 16 bolts.
Torque:
Bolt A and D: 22.1 N

⋅

m (225 kgf

⋅

cm, 16.3 ft

⋅

lbf)

Bolt B and C: 29.4 N

⋅

m (300 kgf

⋅

cm, 21.7 ft

⋅

lbf)

Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)

HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it
can be used after cleaning it.

(d)

Using SST, turn the differential assy right and left 2

 

or 3

times to settle the bearing.
SST

09564-3201 1

(e)

Using SST and a torque wrench, measure the turning
torque of the differential.
SST

09564-3201 1

Turning torque at 60 rpm:
New bearing
0.20 - 0.69 N

⋅

m (2.0 - 7.0 kgf

⋅

cm, 1.8 - 6.1 in.

⋅

lbf)

Used bearing
0.10 - 0.35 N

⋅

m (1.0 - 3.6 kgf

⋅

cm, 0.9 - 3.1 in.

⋅

lbf)

HINT:
If the turning torque is not within the specified value, refer to the
table below to select a thrust washer which turning torque is
within the specified value.

Flange thickness: mm (in.)

Mark

Thickness

Mark

Thickness

0

2.00 (0.0787)

9

2.45 (0.0965)

1

2.05 (0.0807)

A

2.50 (0.0984)

2

2.10 (0.0827)

B

2.55 (0.1004)

3

2.15 (0.0846)

C

2.60 (0.1024)

4

2.20 (0.0866)

D

2.65 (0.1043)

5

2.25 (0.0886)

E

2.70 (0.1063)

6

2.30 (0.0906)

F

2.75 (0.1083)

7

2.35 (0.0925)

G

2.80 (0.1102)

8

2.40 (0.0945)

H

2.85 (0.1122)

D26384

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D25215

90 - 100 

C (194 - 230 

F)

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U150E A/T REPAIR MANUAL   (RM913U)

(f)

Remove the 16 bolts and the transaxle housing.

(g)

Remove the differential assy.

16.

INSTALL FRONT DIFFERENTIAL RING GEAR

(a)

Using ATF and heater, heat the front differential ring gear
to 90 - 110 

C (194.0 - 230.0 

F).

NOTICE:
Do not overheat the ring gear to 110 

C (230.0 

F) or more.

(b)

Clean the contact surface of the front differential case.

(c)

Align the match-marks, install the front differential ring
gear case quickly.

NOTICE:
Do not install the bolts while the ring gear is hot.

(d)

Tighten the 14 bolts.
Torque: 95.1 N

⋅

m (970 kgf

⋅

cm, 70 ft

⋅

lbf)

NOTICE:
Tighten the bolts a little at a time in diagonal order.