Differentials & Axle Shafts: Removal & Installation Lexus LS III

REMOVAL & INSTALLATION

Note. When removal and installation of drive shaft has been performed, always ensure drive shaft joint alignment is correct. See DRIVE SHAFTS article for drive shaft alignment, removal, installation and overhaul.

Note. See RWD AXLE SHAFTS article for axle shaft removal, installation and overhaul.

Removal

Remove differential assembly. See DIFFERENTIAL ASSEMBLY . Measure and note pinion preload. Using a hammer and chisel, raise stakes on companion flange nut. Using holding tool, remove nut and discard. Using seal puller, remove oil seal.

Installation

1. Coat new seal lip with grease and, using Seal Driver Kit (09316-60011) install oil seal until seal outer lip is flush with surface of differential on GS300, GS430 and LS430. On IS300 and RX300 install new oil seal to a depth of .08" (2.0 mm). Using a press and driver kit, install companion flange. Install NEW companion flange nut and gradually tighten nut until correct pinion bearing preload is obtained. See «PINION BEARING PRELOAD»(ref-131964-S22118974822002010200000) table. NOTE: For vehicles with less than 5000 miles, if pinion bearing preload measured before disassembly was more than used bearing specification, return pinion bearing preload to preload measured before disassembly. PINION BEARING PRELOAD Application INCH Lbs. (N.m) GS300, GS430 & LS430 8.6-13.8 (1.0-1.6) IS300 7.8-12.1 (.88-1.37) RX300 7.8-22.6 (.88-2.6)
2. DO NOT exceed maximum torque on companion flange nut when adjusting pinion bearing preload. See «TORQUE SPECIFICATIONS»(ref-131964-S09890087012002010200000) table. DO NOT back off nut to reduce pinion bearing preload. If correct pinion bearing preload cannot be set, replace spacer and repeat procedure. After proper bearing preload is set, stake nut and install drive shaft assembly.

Removal (GS300, GS430 & LS430)

1. Remove front and center exhaust pipes. Remove drive shaft assembly. See «DRIVE SHAFT»(ref-131964-S42742568942002010200000) . Drain differential. On GS300 and GS430, paint match marks on camber adjusting cams and lower suspension arms. Remove nut and bolt, and disconnect both lower suspension arms from axle hub. On LS430, remove 4 bolts and both stabilizer bar brackets. On all models, paint match marks on drive axles and side gear shafts. Remove bolts attaching drive axles to differential. Disconnect drive axles and using wire, suspend drive axles.
2. Support differential using jack. On GS300 and GS430, remove 3 hexagon bolts attaching rear of differential to differential mounting cushion. On LS430, remove 2 bolts attaching rear of differential to differential mounting cushion. On all models, remove 2 bolts attaching front of differential to differential lower mount stoppers. Remove differential assembly from vehicle. Remove upper mount stoppers and shims. Note position and size of adjusting shims for reassembly.

Installation (GS300, GS430 & LS430)

To install, reverse removal procedure. Install 2 bolts attaching front of differential assembly to vehicle. Ensure adjusting shim (if equipped) is installed on top of upper mount stopper. On LS430, use Differential Mounting Cushion Holder (09922-10010) to keep front mounting cushion from twisting during installation and install 2 NEW bolts attaching rear of differential to differential mounting cushion. On GS300 and GS430, install 3 NEW bolts attaching rear of differential to differential mounting cushion and tighten to specification. To install drive axles, see RWD AXLE SHAFTS article. See TORQUE SPECIFICATIONS . Fill differential. See DIFFERENTIAL FLUID CAPACITY table.

Removal (IS300)

1. Remove No. 1 floor board. Drain differential oil. Remove 4 bolts and 2 brackets from rear suspension member. Remove 2 nuts and disconnect stabilizer bar link from stabilizer bar. Use a 5-mm. wrench to prevent ball joint from turning. Remove drive shaft. See DRIVE SHAFTS article. Remove 2 bolts on each suspension member brace and remove brace. Paint match marks on drive axles and side gear shafts. Remove bolts attaching drive axles to differential. Disconnect drive axles and using wire, suspend drive axles.
2. Support differential using jack. Remove 3 hexagon bolts attaching rear of differential to differential mounting cushion. Remove 2 bolts attaching front of differential to differential lower mount stoppers. Remove differential assembly from vehicle. Remove upper mount stoppers and shims.

Installation (IS300)

To install, reverse removal procedure. Install 2 NEW bolts attaching rear of differential to differential mounting cushion. Install 3 bolts attaching rear of differential to differential mounting cushion and tighten to specification. To install drive axles, see RWD AXLE SHAFTS article. Install drive shaft. See TORQUE SPECIFICATIONS . Fill differential. See DIFFERENTIAL FLUID CAPACITY table.

Removal (RX300)

1. Remove axle shafts. See «AXLE SHAFT»(ref-131964-S23231193752002010200000) . Remove drive shaft. See «DRIVE SHAFT»(ref-131964-S42742568942002010200000) . Drain gear oil. Remove 2 bolts from exhaust center pipe and exhaust tail pipe.
2. Support differential with a jack. Loosen 3 rear mounting bolts and dynamic damper. Loosen 2 bolts from rear suspension member and remove 4 nuts, 2 bolts and retainers from rear suspension member. Lower differential with rear suspension member and remove loosened bolts and nuts. Disconnect rear crossmember from differential.

Installation (RX300)

To install, reverse removal procedure. Install bolts and nuts and tighten. See TORQUE SPECIFICATIONS table. To install drive axles, see RWD AXLE SHAFTS article. Install drive shaft. Fill differential. See DIFFERENTIAL FLUID CAPACITY

Drain differential. On LS430 models, disconnect and support exhaust tailpipe. On all models, remove axle shaft. See RWD AXLE SHAFTS article. Using slide hammer and 2 axle shaft mounting bolts, remove side gear shaft. Remove snap ring from side gear shaft, and discard. Using a slide hammer and seal puller, remove side gear shaft oil seal from differential.

Coat new oil seal lip with grease and install using seal driver and handle. Install NEW snap ring to side gear shaft. Using a hammer and a brass bar, install side gear shaft into differential. Use care not to damage side gear shaft or oil seal. Ensure side gear shaft has .08-.12" (2-3 mm) of in and out play. Ensure side gear shaft cannot be pulled out by hand. Install axle shaft. See RWD AXLE SHAFTS article. On LS430 models, install exhaust tailpipe. Fill differential. See DIFFERENTIAL FLUID CAPACITY table.

Scheme 1

Scheme 2

1. Drain differential. Remove differential assembly. See «DIFFERENTIAL ASSEMBLY»(ref-131964-S03971456282002010200000) under REMOVAL & INSTALLATION. Install differential carrier on overhaul stand. Remove 8 differential cover bolts. Using a brass punch and hammer, remove differential cover. (Scheme 1)
2. Using a dial indicator, measure drive pinion runout at a point.39" (9.9 mm) from end of drive pinion. If runout is greater than.0031" (.079 mm), replace drive pinion and ring gear.
3. Using a dial indicator, measure ring gear runout. On GS300, GS430 and LS430, ring gear runout should be less than.0020" (.051 mm). On IS300 and RX300 ring gear runout should be less than.0028" (.07 mm). Replace drive pinion, ring gear and differential case if ring gear runout is greater than maximum wear specifications.
4. Reposition dial indicator and measure ring gear backlash in at least 3 different points. On GS300, GS430 and LS430 ring gear backlash should be within.0031-.0051" (.079-.130 mm). On IS300 and RX300 ring gear backlash should be within.0051-.0071" (.130-.180 mm). Adjust ring gear backlash if difference between minimum and maximum measurements is greater than.0020" (.051 mm), adjust ring gear backlash.
5. For RX300 2 pinion differential, use a dial indicator and measure backlash of side gear while holding one pinion toward differential case. Side gear backlash should be within.0020-.0079" (.05-.20 mm). If backlash is not within specifications, install 2 side gear thrust washers of different thickness.
6. Using an Oil Cooler Relief Valve Socket (09229-55010) and torque wrench, measure drive pinion preload using backlash of drive pinion and ring gear. See «DRIVE PINION SHAFT PRELOAD»(ref-131964-S30699780092002010200000) table.
7. Check total preload with ring gear and pinion gear teeth in contact. See «PINION BEARING PRELOAD»(ref-131964-S22118974822002010200000) table. If preload is not within specification, disassemble and inspect differential. Measure pinion gear backlash while holding one side gear toward case. (Scheme 6) If pinion gear backlash is not within specifications, install correct thrust washer when reassembly is performed.
8. Check tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION.
9. On IS300 and RX300, unstake and remove companion flange nut and companion flange. Remove front oil seal and front bearing. If equipped with Torque Sensing LSD, remove 2 snap rings from 2 side gear shafts. (Scheme 2) Remove side gear shafts. (Scheme 4)or (Scheme 5).
10. On GS300, GS430 and LS430, using slide hammer, remove both side gear shafts. Remove side gear shaft snap rings, and discard. Using seal puller, remove side gear shaft oil seals from differential case. Remove 8 differential carrier retainer bolts from each side. Using puller and replacer, remove differential carrier retainers and washers. (Scheme 3)
11. Remove differential case from differential carrier while lifting ring gear side upward. On GS300, GS430 and LS430, remove "O" rings from differential carrier retainers. Using a press, adapter and handle, remove 2 side bearing outer races and adjusting plate washers from differential carrier retainers.
12. On GS300, GS430 and LS430, unstake and remove drive pinion nut. Using a press, remove drive pinion with rear bearing. Remove companion flange. DO NOT allow drive pinion to drop. Remove spacer from drive pinion. Using seal puller, remove oil seal. Remove oil slinger and drive pinion front bearing. (Scheme 3) Using a press and Bearing Remover (09950-00020), remove rear bearing from drive pinion.
13. If replacing drive pinion front bearing, remove front bearing race and adjusting washer from differential carrier using a hammer and brass punch. Measure and note thickness of adjusting washer for reassembly.
14. Using Puller Set (09950-40011), remove side bearings from differential case. (Scheme 7) Paint match marks on ring gear and differential case. DO NOT use punch marks. Remove 10 ring gear bolts. Using a plastic hammer, separate ring gear from differential case. Using a pin punch, remove differential case straight pin. Remove pinion shaft, 2 pinion gears, 2 pinion gear thrust washers, 2 side gears and 2 side gear thrust washers. (Scheme 3)- (Scheme 5).
15. If replacing companion flange dust deflector, remove old dust deflector from companion flange, and install NEW dust deflector using a press and adapter. If replacing side gear shaft dust covers, remove old dust cover from side gear shafts using a press and adapter. Install NEW dust cover using a press and adapter. Ensure dust cover fits tightly against side gear shaft flange.

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Install 2 side gears with proper size thrust washers, 2 pinion gears with pinion gear thrust washers and pinion shaft, into differential case. Temporarily install 2 side gear shafts into differential case. (Scheme 3)- (Scheme 5). Use proper side gear thrust washers to ensure proper pinion gear backlash is obtained.
2. On GS300, GS430 and LS430, measure pinion gear backlash while holding one side gear toward case. (Scheme 6) Maximum pinion gear backlash is.0059" (.15 mm). Side gear thrust washers are available in 9 different sizes from.059" (1.5 mm) to.075" (1.9 mm) thickness. If backlash is not within specification, replace side gear thrust washers with different thicknesses. Differential gears should be able to rotate. After proper pinion gear backlash is obtained, remove side gear shafts and install straight pin into pinion gear shaft, and stake differential case.
3. On IS300 and RX300, measure side gear backlash while holding 1 pinion gear toward differential case. Maximum side gear backlash is.0020-.0079" (.05-.20 mm). If backlash is not within specification, replace side gear thrust washers with different thicknesses. Using a pin punch and hammer, install straight pin through differential case and hole of pinion shaft. Using a chisel and hammer, stake outside of differential case pin hole.
4. On all models, heat ring gear in boiling water. Remove ring gear from water, and allow water to evaporate completely. Quickly install ring gear, aligning match marks. Temporarily install 2 ring gear bolts to align ring gear and differential case. Tighten by hand. Allow ring gear to cool. Apply Loctite to threads of NEW ring gear bolts, and install.
5. Tighten NEW ring gear bolts uniformly, a little at a time, in diagonally opposite pairs. See «TORQUE SPECIFICATIONS»(ref-131964-S09890087012002010200000). On GS300, GS430 and LS430, when specified torque is reached, tighten bolts an additional 60-90 degrees. On IS300 and RX300, using a chisel and hammer, stake 4 lock plates. Press side bearings onto differential case using adapter.
6. On IS300 and RX300, install differential case on carrier and install 2 plate washers so there is no play in bearing. Install bearing caps. Using a dial indicator, measure ring gear runout. The maximum runout is.0028" (.07 mm). Remove 2 bearing caps, 2 plate washers and differential carrier.
7. On all models, using a press and adapter, install drive pinion front bearing outer race into differential carrier. Using a press and adapter, install NEW adjusting washer (the same thickness as the one removed) and rear bearing outer race into differential carrier. Using a press and adapter, install rear bearing onto drive pinion.
8. Temporarily position drive pinion in differential carrier. Using a press and adapter, install front bearing onto drive pinion. Assemble spacer and oil seal after adjusting tooth contact pattern. Install oil slinger. Using a press and adapter, install companion flange onto drive pinion. (Scheme 3) Temporarily adjust drive pinion preload by tightening companion flange nut while holding companion flange with tool. Gradually tighten companion flange nut until preload torque specification is reached. See «TORQUE SPECIFICATIONS»(ref-131964-S09890087012002010200000) table. Measure preload at start of turning. See «DRIVE PINION SHAFT PRELOAD»(ref-131964-S30699780092002010200000) table. DO NOT overtighten companion flange nut. DRIVE PINION SHAFT PRELOAD Application INCH Lbs. (N.m) GS300, GS430 & LS430 New Bearing 13.0-15.6 (1.5-1.8) Used Bearing (1) 4.3-6.9 (.49-.78) IS300 New Bearing 8.7-13.9 (.98-1.57) Used Bearing (1) 4.3-6.9 (.49-.78) RX300 New Bearing 9.6-14.8 (1.1-1.7) Used Bearing (1) 5.2-7.8 (.6-.9) (1) On vehicles with 5000 miles or less, if preload is greater than specification, adjust preload to measurement made prior to disassembly.
9. On GS300, GS430 and LS430, using a press and adapter, install 2 side bearing adjusting plate washers and outer bearing races in differential case. Install drive side bearing in differential carrier first, then install differential case. Using a hammer and adapter, install 2 carrier retainers aligning match marks. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131964-S09890087012002010200000).
10. On IS300 and RX300, place 2 bearing outer races on their respective bearings. Ensure left and right races are NOT interchanged. Install plate washer on backside of ring gear. Snug down washer and bearing by tapping on ring with a plastic hammer. Using a dial indicator, hold companion flange and measure ring gear backlash. Ensure backlash is within.0051-.0071" (.13-.18 mm) by selecting and installing correct plate washer thickness. Select a ring gear teeth side washer so there is no clearance between outer race and case. Remove plate washer and differential case. Install plate washer to ring gear back side. Place outer plate washer onto differential case together with outer race, and install differential case with outer race into carrier. Using a plastic hammer, snug down washer and bearing by tapping ring gear. Using a dial indicator, measure ring gear backlash in at least 3 different positions.
11. On GS300, GS430 and LS430, using a dial indicator, measure ring gear backlash in at least 3 different positions. Adjust ring gear backlash if average measurement is not within.0031-.0051" (.079-.130 mm). If the difference between minimum and maximum measurements is greater than.002" (.051 mm), adjust ring gear backlash. To adjust ring gear backlash, replace adjusting washer on ring gear side with one of a different thickness. NOTE: When replacing adjusting washers, always use NEW washers.
12. On IS300 and RX300, Remove teeth side plate washer and measure and record thickness. Install a new washer.0024-.0035" (.06-.09 mm) thicker than the removed washer. Using a hammer, tap in plate washer. Align match marks on bearing cap and differential carrier, and install 2 bearing caps and 4 bolts. Recheck ring gear backlash. If not within specification adjust by increasing or decreasing washer thickness on both sides by equal amount.
13. Measure drive pinion total preload with teeth of ring and pinion gears in contact. See «PINION BEARING PRELOAD»(ref-131964-S22118974822002010200000). If preload is greater than specification, use a thinner washer. There are 43 different adjusting plate washers with thicknesses between.0795" (2.02 mm) to.1126" (2.86 mm) in.0008" (.020 mm) increments. Changing washer thickness by.0008" (.020 mm) will change total preload by approximately.9 INCH lbs. (.1 N.m). Changing snap ring thickness by.0008" (.020 mm) will change total preload by.9 INCH lbs. (.1 N.m).
14. When drive pinion total preload is within specification, check tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If tooth contact pattern is not correct, select a different thickness pinion adjusting washer. Adjusting washers are available in 42 different thicknesses between.0736" (1.87 mm) to.0898" (2.281 mm), in.004" (.10 mm) increments.
15. When tooth contact pattern has been corrected and pinion total preload and ring gear backlash are within specification, remove differential retainers, differential case and drive pinion. Install NEW spacer on drive pinion. Install drive pinion and front bearing. Install oil slinger. Apply grease to lip of NEW oil seal, and install oil seal until flush with differential carrier.
16. On GS300, GS430 and LS430, press companion flange onto drive pinion shaft using care. DO NOT damage oil seal. Coat threads of drive pinion shaft and nut with gear oil, and install nut. Gradually tighten nut to 106 INCH lbs. (12 N.m) until drive pinion preload is within specification. See «DRIVE PINION SHAFT PRELOAD»(ref-131964-S30699780092002010200000) table. Maximum drive pinion shaft nut torque is 362 ft. lbs. (491 N.m). DO NOT overtighten nut. DO NOT back off on nut to reduce preload. If preload is greater than specification, replace spacer and repeat procedure.
17. On IS300 and RX300, remove companion flange and front bearing and install new bearing spacer and front bearing on drive pinion. Apply grease and install new front oil seal to a depth of.079" (2 mm). Install companion flange on drive pinion. Hold companion flange and torque drive pinion nut. See «TORQUE SPECIFICATIONS»(ref-131964-S09890087012002010200000) table. Check drive pinion preload. See «DRIVE PINION SHAFT PRELOAD»(ref-131964-S30699780092002010200000) table. If preload is greater than specification, replace bearing spacer. If preload is less than specification, gradually retighten nut with 9 ft. lbs. (13 N.m) of torque until specified torque is reached. If maximum torque is exceeded while retightening the nut, replace bearing spacer and repeat preload adjusting procedure. DO NOT loosen pinion nut to reduce preload. Recheck total preload, ring gear backlash and tooth contact between ring gear and drive pinion. Ensure companion flange runout is within specifications and stake drive pinion nut. Coat carrier retainer oil seal lip with grease, and install into carrier retainers
18. On GS300, GS430 and LS430, measure drive pinion shaft runout.39" (10 mm) from end of shaft. Maximum runout is.0031" (.079 mm). Install differential case into carrier. Coat NEW carrier retainer "O" ring with gear oil and install "O" ring to carrier retainers. Coat carrier retainer oil seal lip with grease, and install into carrier retainers. Install carrier retainers. Recheck backlash, total preload and tooth contact pattern. If settings are within specification, stake drive pinion shaft nut.
19. On all models, install NEW snap ring to side gear shafts, and coat with grease. Using brass bar and hammer, install side gear shafts. Pull side gear shaft with hands to ensure it is firmly seated. Remove differential carrier from overhaul stand.
20. Clean differential cover and differential contact area. Apply Sealant (08826-00090) to differential carrier or cover. (Scheme 8) Install 8 cover bolts and breather plug, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-131964-S09890087012002010200000). Wait one hour before filling differential with gear oil or operating vehicle. See «DIFFERENTIAL FLUID CAPACITY»(ref-131964-S08275465162002010200000) table. To complete installation, reverse removal procedure.