Differentials & Drive Axles: Other Lexus RX I

Lubricant Type

Use API GL-5. For temperatures above 0°F (-18°C), use SAE 90. For temperatures below 0°F (-18°C), use SAE 80W or 80W-90.

TOOTH CONTACT BETWEEN RING GEAR & DRIVE PINION

1. Coat 3 or 4 teeth at 3 different positions on the ring gear with Red lead primer.
2. Hold the companion flange firmly and rotate the ring gear in both directions.
3. Inspect the tooth contact pattern. (Scheme 41)
4. If the teeth are not contacting properly, use (Scheme 42) to select a proper washer for correction. (Scheme 43)

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

1. Raise and support vehicle. Drain hypoid gear oil.
2. Remove driveshaft. See «DRIVESHAFTS»(ref-8483) article.
3. Using a chisel and hammer, unstake the staked part of the nut. Using a companion flange holding tool, remove the nut. (Scheme 44) Using puller A set, remove the companion flange. (Scheme 45)
4. Remove front oil seal and oil slinger. Using a oil seal puller, remove the oil seal. Remove the oil slinger. (Scheme 46)
5. Remove front bearing and bearing spacer. Using drive pinion front bearing remover, remove front bearing. Remove the bearing spacer. (Scheme 47)

Scheme 46

Scheme 47

Scheme 48

Scheme 49

1. Install new bearing spacer and front bearing on the shaft.
2. Install new oil slinger and oil seal using a differential oil seal replacer. Oil seal drive in depth should be 2 mm (0.079"). Coat MP grease to the oil seal lip. (Scheme 48)
3. Using a puller A set, install the companion flange on the shaft. (Scheme 49) Coat the threads of a new nut with hypoid gear oil. Using a companion flange holding tool to hold the flange, torque the nut to 80 ft. lbs. (108 N.m).
4. Adjust drive pinion preload. Drive pinion preload is described under step 15 of FINAL REASSEMBLY under OVERHAUL of REAR DIFFERENTIAL CARRIER.
5. Stake drive pinion nut.
6. Install propeller shaft. See «DRIVESHAFTS»(ref-8483) article.
7. Install filler plug and torque to 36 ft. lbs. (49 N.m). Fill differential with correct fluid. See «LUBRICATION»(ref-151104-S15824428312002121100000). see scheme 5

Adjusting Drive Pinion Preload(Without Differential Case In Carrier)

Using a companion flange holding tool, torque the flange nut to 80 ft. lbs. (108 N.m). Since there is no spacer, torque a little at a time, being careful not to overtighten it. Using a torque wrench, measure the preload. see scheme 25 Preload should be within specification. See DRIVE PINION PRELOAD SPECIFICATIONS (DIFFERENTIAL CASE NOT INSTALLED) table.

DRIVE PINION PRELOAD SPECIFICATIONS (DIFFERENTIAL CASE NOT INSTALLED)

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

1. Place the 2 bearing outer races on their respective bearings. Make sure the left and right races are not interchanged. Install the differential case in the carrier. (Scheme 53)
2. Install only the plate washer on the ring gear back side. Snug down the washer and bearing by tapping on the ring gear with a hammer. Using a dial indicator, hold the companion flange and measure the ring gear backlash. (Scheme 54) Select a ring gear back side plate washer so that the backlash is 0.0051" (0.13 mm). Select a ring gear teeth side washer so that there is no clearance between the outer race and case.
3. Remove the plate washer and differential case.Install the plate washer to the ring gear back side.
4. Place the outer plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier. Using a plastic hammer, snug down the washer and bearing by tapping the ring gear.
5. Using a dial indicator, hold the companion flange and measure the ring gear backlash. (Scheme 54) Ring gear backlash should be 0.0051-0.0071" (0.13-0.18 mm). If it is not within the specification, adjust it by either increasing or decreasing the thickness of washers on both sides by an equal amount. There should be clearance between the plate washer and case. Ensure ring gear backlash is still within specification.
6. To adjust side bearing preload, remove the teeth side plate washer. Using a micrometer, measure the thickness of the removed plate washer. Install a new washer 0.0024-0.0035" (0.06-0.09 mm) thicker than the removed washer. Select a washer which can be pressed in 2/3 of the way by finger. Using a differential side bearing replacer and a hammer, tap in the plate washer.
7. Align the matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps and 4 bolts. Tighten bolts to a torque of 58 ft. lbs. (79 N.m). Recheck the ring gear backlash. Ring gear backlash should be 0.0051-0.0071" (0.13-0.18 mm). If it is not within specification, adjust it by either increasing or decreasing the washers thickness on both sides by equal amount. The backlash will change by about.0008" (.02 mm) corresponding to.0012" (.03 mm) change in the plate washer thickness. (Scheme 55)
8. Using a torque wrench, measure the TOTAL preload. Total preload at starting should be a combination of the drive bearing preload plus 2.6-4.3 INCH lbs. (0.3-0.5 N.m).
9. Inspectand adjust tooth contact between ring gear and drive pinion. See «TOOTH CONTACT BETWEEN RING GEAR & DRIVE PINION»(ref-151104-S27529510102002121800000) under ADJUSTMENTS.
10. Remove companion flange. Remove front bearing.
11. Install new bearing spacer and front bearing on the drive pinion.
12. Install oil slinger.
13. Using a differential oil seal replacer and a hammer, install a new oil seal. Oil seal drive in depth should be 0.079" (2 mm). (Scheme 48) Coat MP grease to the oil seal lip.
14. Using Puller A Set, install the companion flange on the drive pinion. see scheme 53 Coat the threads of a NEW companion flange nut with hypoid gear oil. Using a companion flange holding tool to hold the flange, torque the nut to 80 ft. lbs. (108 N.m).
15. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload at STARTING should be as follows: New bearing: 9.6-14.8 INCH lbs. (1.1-1.7 N.m) Reused bearing: 5.2-7.8 INCH lbs. (0.6-0.9 N.m) If preload is greater than specified, replace the bearing spacer. If the preload is less than specified, re-torque the nut with 9 ft. lbs. (13 N.m) of torque at a time until the value of 174 ft. lbs. (235 N.m) or less is reached. If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do NOT loosen the pinion nut to reduce the preload.
16. Recheck total preload.
17. Recheck ring gear backlash.
18. Recheck tooth contact between ring gear and drive pinion.
19. Check companion flange runout. Using a dial indicator, measure the runout of the companion flange vertically and horizontally. Maximum runout should not exceed 0.0039" (0.10 mm). see scheme 21
20. Stake drive pinion nut.
21. Using a replacer, and handle set and a hammer, install 2 new oil seals until they are flush with the carrier end surface. Coat MP grease to the oil seal lip. see scheme 54
22. Install 2 NEW snap rings to the side gear shafts. Using a differential side gear shaft puller, install the 2 side gear shafts until they contact the pinion shaft. Check that the shaft is fully inserted by confirming the noise it should make when it is tapped.
23. Install the 2 side gear shafts to the differential case. Using needle nose pliers, install 2 new snap rings to the 2 side gear shafts. see scheme 55
24. Install the oil deflector and bolt to the carrier cover. Tighten to a torque of 65 ft. lbs. (7.4 N.m). Install the breather plug to the carrier cover. Tighten to a torque of 15 ft. lbs. (21 N.m). Clean contacting surfaces of any residual liquid gasket material using gasoline or alcohol. Apply liquid gasket Three Bond 1281, or equivalent, to the carrier. see scheme 56 Instal the carrier cover within 3 minutes after applying liquid gasket. Torque the 8 bolts to 34 ft. lbs. (47 N.m).