1998 lexus lx 450 (lx450) service repair manual

1997 Lexus LX 450 DIFFERENTIAL & AXLE SHAFTS 1997 DRIVE AXLES Lexus/Toyota Differentials & Axle Shafts

DIFFERENTIAL & AXLE SHAFTS 1997 DRIVE AXLES Lexus/Toyota Differentials & Axle Shafts

AXLE RATIO & IDENTIFICATION Axle ratio may be determined by dividing number of ring gear teeth by number of teeth on drive pinion.

Vehicles delivered from manufacturer with large tires have a higher numerical axle ratio. Equipping vehicles with larger diameter tires may alter axle ratio from factory specification.

DESCRIPTION & OPERATION NOTE:

For Electronic Locking Differential (ELD) electronic controls testing, see DIFFERENTIAL - ELECTRONIC LOCKING in DRIVE AXLES.

Drive axle assembly is a hypoid gear type with separate carrier housing. Drive pinion transfers power to the ring gear which provides power to the side gears and axle shafts.

Some models may be equipped with Electronic Locking Differential (ELD) system. See DIFFERENTIAL ELECTRONIC LOCKING article in DRIVE AXLES.

LUBRICATION CAPACITY DIFFERENTIAL FLUID CAPACITY (1) Quantity: Qts. (L)

Application Front Axle With Electronic Locking Differential Without Electronic Locking Differential Rear Axle (1) Approximate quantity listed.

2.9 (2.7) 3.0 (2.8) 3.5 (3.3)

FLUID TYPE For temperatures greater than 0°F (-18°C), use SAE 90W GL-5 hypoid gear oil. For temperatures 0°F (-18°C) or less, use SAE 80W-90 GL-5 hypoid gear oil.

TROUBLE SHOOTING NOTE:

See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

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1997 Lexus LX 450 DIFFERENTIAL & AXLE SHAFTS 1997 DRIVE AXLES Lexus/Toyota Differentials & Axle Shafts

REMOVAL & INSTALLATION FRONT AXLE SHAFT R & I Removal

1. On models equipped with Electronic Locking Differential (ELD), turn ignition switch to ON position.

Turn differential lock control switch to FR/RR position and lock front differential. Rotate tires to ensure differential is locked. Turn ignition off. Disconnect negative battery cable.

2. On all models, raise and support vehicle. Remove front wheel. Disconnect brakeline from brake caliper.

Remove brake caliper. Remove grease cap from flange hub. See Fig. 1 . Remove snap ring from end of front axle shaft. Remove flange hub nuts.

3. Using brass drift and hammer, tap on studs to free cone washers from studs and flange hub. Remove cone washers, flange hub and gasket. Bend over tabs on lock washer. Remove wheel bearing lock nut, lock washer, wheel bearing adjusting nut, thrust washer and outer wheel bearing. See Fig. 1 . Remove axle hub with brake disc and inner wheel bearing.

4. Remove oil seal and inner wheel bearing from axle hub (if necessary). Drive bearing races from axle hub (if replacement is required). Remove dust cover/spindle bolts. Remove dust seal, gasket and dust cover.

5. Using brass drift and hammer, tap spindle from steering knuckle. Remove gasket. Position flat area on outer end of front axle shaft facing upward.

6. Remove front axle shaft from axle housing. Remove oil seal from axle housing. Remove bushing from inside of spindle (if necessary). If necessary to disassemble front axle shaft, see FRONT AXLE SHAFT OVERHAUL under OVERHAUL.

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Fig. 1: Identifying Front Axle Shaft & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Installation

1. Using Seal Installer (SST 09618-60010), install NEW oil seal into axle housing. Install NEW bushing into spindle (if removed).

2. Position flat area on outer end of front axle shaft facing upward. Install front axle shaft. Pack cavity of steering knuckle with grease so cavity is about 3/4 full with grease. Install NEW gasket on steering knuckle.

3. Install spindle on steering knuckle. Install dust cover, NEW gasket and dust seal on steering knuckle.

Install and tighten dust cover/spindle bolts to specification. See TORQUE SPECIFICATIONS .

4. Pack inner and outer wheel bearings with grease. Coat inside of axle hub with grease. Install inner wheel bearing and NEW oil seal on axle hub. Lightly coat lip of oil seal with grease.

5. Install axle hub with brake disc on spindle. Install outer wheel bearing and thrust washer. Install and tighten wheel bearing adjusting nut to 43 ft. lbs. (58 N.m). Rotate axle hub several times in each direction. Retighten wheel bearing adjusting nut to 43 ft. lbs. (58 N.m). Loosen wheel bearing adjusting nut until nut is finger tight.

6. Using spring scale attached to wheel lug nut stud, check wheel bearing preload by measuring torque required to start rotation of axle hub. Wheel bearing preload should be 6.2-12.6 lbs. (2.8-5.7 kg).

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7. Install NEW lock washer. Install wheel bearing lock nut. Tighten wheel bearing lock nut to 47 ft. lbs. (64 N.m). Recheck wheel bearing preload, ensuring wheel bearing preload is 6.2-12.6 lbs. (2.8-5.7 kg). If wheel bearing preload is not within specification, adjust bearing preload by tightening or loosening wheel bearing adjusting nut.

8. Once correct wheel bearing preload is obtained, bend one tab on lock washer inward and another tab outward. Apply grease on splines at end of front axle shaft.

9. Using NEW gasket, install flange hub, cone washers and washers. Install and tighten flange hub nuts to specification. See TORQUE SPECIFICATIONS . Install bolt in end of front axle shaft. Pull front axle shaft outward far enough for installation of snap ring. Install snap ring on end of front axle shaft.

10. Remove bolt from end of front axle shaft. Install grease cap. To install remaining components, reverse removal procedure. Use NEW gaskets when installing brakeline on brake caliper.

11. On models equipped with Electronic Locking Differential (ELD), ensure bleeder plug at point of bleeder tube, located inside of engine compartment, is not damaged. Tighten bolts/nuts to specification. Bleed brake system. See appropriate BRAKE SYSTEM article in BRAKES. STEERING KNUCKLE Removal

1. Remove front axle shaft. See FRONT AXLE SHAFT R & I under REMOVAL & INSTALLATION. Disconnect tie rod end from knuckle arm. See Fig. 1 . Remove bolts and oil seal end retainer from rear of steering kn uckle. Remove knuckle arm and bearing cap bolts/nuts from steering knuckle.

2. Using Bearing Remover/Installer (SST 09606-60020), press bearing cap, shims and knuckle arm from steering knuckle. See Fig. 2 .

3. Remove upper and lower bearings from steering knuckle. Note location of shims and both bearings for reassembly reference. Remove steering knuckle from axle housing.

4. Remove bearing races from end of axle housing (if necessary). Remove oil seal for front axle shaft from end of axle housing.

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Fig. 2: Removing Steering Knuckle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Installation

1. Install NEW bearing races in end of axle housing (if removed). Install NEW oil seal for front axle shaft in end of axle housing. Ensure oil seal end retainer is installed on axle housing.

2. Install oil seal set on axle housing. Oil seal set should be installed on axle housing in following sequence: felt dust seal, rubber seal and then steel ring.

3. Pack upper and lower bearings with molybdenum disulfide lithium based grease. Position bearings in original location on steering knuckle. Install steering knuckle on axle housing. Using bearing remover/installer, support bearing race for upper bearing.

4. Install shims and bearing cap. Using hammer, tap bearing cap into bearing race. Using bearing remover/installer, support bearing race for lower bearing.

5. Install knuckle arm on bottom of steering knuckle. Using hammer, tap knuckle arm into bearing race for lower bearing. Remove bearing remover from steering knuckle.

6. Install cone washers, washers and nuts on knuckle arm. Install washers and bolts on bearing cap. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS .

7. Using spring scale attached to tie rod end opening on knuckle arm, measure steering knuckle bearing preload required to start rotation of steering knuckle. Steering knuckle bearing preload should be 5.6-9.9 Microsoft Thursday, August 27, 2009 1:51:00 PM

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lbs. (2.5-4.5 kg).

8. If bearing preload is not within specification, adjust bearing preload by increasing or decreasing thickness of shim(s). Shims are available in thickness of .004" (0.10 mm), .008" (0.20 mm), .020" (0.50 mm) and .039" (1.00 mm).

9. Once correct bearing preload is obtained, install bolts in oil seal end retainer. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS .

REAR AXLE SHAFT Removal & Installation

1. Raise and support vehicle. Drain differential gear oil. Remove 6 nuts and plate washers from axle shaft end. See Fig. 3 . Using brass drift and hammer, strike center of axle shaft to loosen and remove cone washers.

2. Install 2 bolts in threaded holes provided on axle shaft end. Tighten each bolt evenly, and remove axle shaft. Remove and discard axle shaft gasket.

3. Using dial indicator, check rear axle shaft runout at center of rear axle shaft. Replace rear axle shaft if runout exceeds .031" (0.80 mm). Using slide hammer, remove oil seal.

4. To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS . Fill differential with gear oil. See DIFFERENTIAL FLUID CAPACITY table under LUBRICATION.

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1997 Lexus LX 450 DIFFERENTIAL & AXLE SHAFTS 1997 DRIVE AXLES Lexus/Toyota Differentials & Axle Shafts

Fig. 3: Exploded View Of Rear Hub & Axle Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR HUB ASSEMBLY, OIL SEAL & BEARING Microsoft Thursday, August 27, 2009 1:51:00 PM

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Removal

1. Remove rear wheels. Remove rear axle shaft. See REAR AXLE SHAFT. Remove brake caliper and wire aside. Remove brake rotor and rear ABS speed sensor. Remove axle bearing lock nut screws and lock nut.

See Fig. 3 . Remove lock nut plate and outer bearing. Remove axle hub.

2. Place axle hub in a vise. Using side hammer, remove oil seal and inner bearing from hub. Using a brass drift and hammer, remove both outer and inner bearing outer races. DO NOT damage ABS speed sensor rotor.

Installation

1. Using press, press in NEW outer races. Pack NEW outer and inner bearings with multipurpose grease.

Coat inside of hub with multipurpose grease.

2. Install inner bearing and NEW oil seal. Coat lip of oil seal with grease. Install hub and outer bearing.

Install lock nut plate and lock nut. Install rotor and temporarily install 2 hub nuts.

3. Torque bearing lock nut to 43 ft. lbs (58 N.m). Turn hub several times to set bearings. Re-torque bearing lock nut to specification. Loosen lock nut until it can be turned be hand.

4. Using a spring tension gauge, check preload and tighten lock nut until preload is 5.7-12.8 lbs. (2.6-5.8 kg). Ensure parking brake is completely disengaged. Align marks on bearing lock nut and end of axle housing. See Fig. 4 . Ensure lock nut preload is still within specification.

5. Check distance between end surface of axle housing and lock nut. See Fig. 5 . Distance should be .008.035" (0.20-0.90 mm). If distance is greater than specified, go back to step 3) and readjust lock nut. If distance is not greater than specified, go to next step.

6. Ensure that hub and rotor rotate smoothly and hub has no axial play. Install bearing lock nut screws. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. Fill differential with gear oil. Check ABS speed sensor signal.

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Fig. 4: Aligning Bearing Lock Nut & Axle Housing (Rear Hub Assembly) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 5: Checking Distance Between Surface Of Axle Housing & Lock Nut (Rear Hub Assembly) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DRIVE SHAFTS Removal & Installation (Front & Rear)

1. Place reference marks on front drive shaft companion flange and front differential for reassembly reference. Place reference marks on front drive shaft companion flange and transfer case. Remove drive shaft companion flange bolts/nuts from front drive shaft. Remove front drive shaft.

2. Place reference marks on rear drive shaft companion flange and rear differential for reassembly reference.

Place reference marks on rear drive shaft companion flange and transfer case. Remove drive shaft companion flange bolts/nuts from front drive shaft. Remove rear drive shaft.

3. To install, reverse removal procedure. Ensure reference marks are aligned. Tighten bolt/nuts to Microsoft Thursday, August 27, 2009 1:51:00 PM

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specification. See TORQUE SPECIFICATIONS .

PINION FLANGE & OIL SEAL Removal (Front & Rear Differentials)

1. Drain differential oil. Disconnect front or rear drive shaft-to-differential companion flanges. See DRIVE SHAFTS . Wire drive shaft aside.

2. Using hammer and chisel, loosen staked area on drive pinion nut. Remove drive pinion nut and washer (if equipped).

3. Using puller, remove companion flange from drive pinion. Using puller, remove oil seal from differential carrier. Note direction of oil slinger installation (if equipped). Remove oil slinger. Using puller, remove front bearing from drive pinion.

4. Using slide hammer, remove bearing race for front bearing from differential carrier. On front differentials, remove oil storage ring, located on front side of spacer on drive pinion.

5. On all models, remove and discard spacer from drive pinion. See Fig. 6 .

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Fig. 6: Exploded View Of Typical 2 & 4-Pinion Type Differential Assembly Without ELD (Front Shown; Rear Is Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Always replace spacer whenever drive pinion nut is loosened or removed.

Installation

1. Install NEW spacer on drive pinion. On front differentials, drive NEW oil storage ring onto front side of drive pinion spacer. Ensure oil slinger is installed with concave side facing toward front bearing.

2. Install NEW oil seal to correct depth in differential carrier. Correct depth is .039" (1.00 mm). Apply grease on lip of oil seal. Apply grease to threads of NEW drive pinion nut.

3. Tighten drive pinion nut to MINIMUM specification. See TORQUE SPECIFICATIONS . Using Microsoft Thursday, August 27, 2009 1:51:00 PM

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INCH-lb. Torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of just drive pinion to determine drive pinion bearing preload. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

4. If drive pinion rotating torque exceeds specification, replace spacer and repeat procedure. If drive pinion rotating torque is less than specified, tighten drive pinion nut in small increments until correct rotating torque is obtained. DO NOT exceed MAXIMUM drive pinion nut torque. If maximum torque is exceeded, replace spacer and repeat procedure. DO NOT back off drive pinion nut.

5. Once correct drive pinion rotating torque is obtained, stake drive pinion nut against drive pinion. To install remaining components, reverse removal procedure. Ensure reference marks on drive shaft companion flanges are aligned. Tighten bolts/nuts to specification. Fill differential with gear oil.

DIFFERENTIAL ASSEMBLES Removal

1. On models equipped with Electronic Locking Differential (ELD), turn ignition switch to ON position.

Turn differential lock control switch to FR/RR position and lock front/rear differential. Rotate tires to check if differential is locked. Turn ignition off. Disconnect negative battery cable.

2. On all models, raise and support vehicle. Remove drive shaft. See DRIVE SHAFTS . Drain differential gear oil.

3. Remove axle shafts. See FRONT AXLE SHAFT R & I or REAR AXLE SHAFT under REMOVAL & INSTALLATION. Remove tie rod assembly.

4. On rear ELD, remove actuator cover. Remove vent hose. Disconnect electrical connectors.

5. Remove differential carrier-to-axle housing nuts and washers. Remove differential carrier and gasket from axle housing.

Installation

To install, reverse removal procedure using NEW gasket. Ensure reference marks on drive shaft companion flanges are aligned. Ensure differential vent tube end, located in engine compartment, is not damaged or plugged. Install vent tube at a depth of .59" (15 mm). Tighten bolts/nuts to specification. Fill differential with gear oil. Check differential lock operation.

OVERHAUL NOTE:

AXLE ASSEMBLY SPECIFICATIONS table is located at end of article.

FRONT AXLE SHAFT OVERHAUL Disassembly

1. Mount inner end (long end) of front axle shaft in soft-jaw vise. Using hammer and brass drift placed against inner race, drive outer end of front axle shaft from inner end of front axle shaft. See Fig. 7 .

2. Remove snap rings from inner end of front axle shaft. Tilt cage and inner race outward, and remove 6 balls.

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3. Position cage with large openings against protruding areas on outer end of front axle shaft. Perform STEP 1. See Fig. 8 . Remove cage and inner race from inner end of front axle shaft.

4. Separate inner race from cage. Perform STEP 2. See Fig. 8 . Inspect components for damage.

Fig. 7: Separating Axle Shaft (Front) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 8: Removing & Installing Cage & Inner Race (Front) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Reassembly Microsoft Thursday, August 27, 2009 1:51:00 PM

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1. Coat inner race, cage, balls and inner area of outer end of front axle shaft with molybdenum disulfide lithium-based grease. Install inner race in cage so protruding end of inner race is toward wide area of cage. Go to step 3). See Fig. 8 .

2. Install cage and inner race in outer end of front axle shaft. Ensure protruding end of inner race and wide area on cage are facing outward. Go to step 4). See Fig. 8 . Install 6 balls into cage.

3. Pack joint assembly and area of outer end of front axle shaft with molybdenum disulfide lithium-based grease. Install NEW snap rings on end of inner end of front axle shaft.

4. Mount outer end of front axle shaft in soft-jaw vise with cage and inner race facing upward. Compress snap rings on inner end of front axle shaft and install inner end of front axle shaft into outer end of front axle shaft. Ensure inner end of front axle shaft cannot be pulled from outer end of front axle shaft.

DIFFERENTIAL ASSEMBLY (2-PINION) Disassembly (Front & Rear)

1. Using dial indicator, check vertical and lateral runout on companion flange while rotating companion flange. See Fig. 9 . Replace companion flange if vertical or lateral runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS .

2. Using dial indicator, check ring gear runout at backside of ring gear while rotating ring gear. See Fig. 10 .

Replace ring gear and drive pinion as a set if ring gear runout exceeds specification.

3. Using dial indicator, check ring gear backlash at 3 places, by rotating ring gear back and forth while holding drive pinion from rotating. Ring gear backlash should be within specification.

4. Using dial indicator, check side gear backlash while holding one side gear against differential case. See Fig. 10 . Side gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS. If side gear backlash is not within specification, different thickness thrust washer must be installed on side gear.

5. On all models, check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. 6. Using INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of just drive pinion to determine drive pinion bearing preload for reassembly reference. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

7. Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear for reassembly reference. Total assembled preload should be within specification.

8. On all models, using hammer and chisel, loosen stake area on drive pinion nut. Remove drive pinion nut and washer (if equipped). Discard drive pinion nut.

9. Using puller, remove companion flange from drive pinion. Using puller, remove and discard oil seal from differential carrier.

10. Note direction of oil slinger installation. Remove oil slinger. Using puller, remove front bearing from drive pinion.

NOTE:

It may be necessary to remove bearing race for front bearing from differential carrier before spacer can be removed from drive pinion. On

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front differential applications, an oil storage ring is located on front side (companion flange side) of spacer. Oil storage ring must be removed before spacer can be removed.

11. Remove spacer from drive pinion. See Fig. 6 . Place reference mark on side bearing caps and differential carrier for reassembly reference.

12. Remove and discard adjusting nut locks located on each side bearing cap. Remove side bearing caps, adjusting nuts and bearing races for side bearings.

13. Remove differential case with ring gear, side bearing race and adjusting nuts from differential carrier.

Mark adjusting nuts and side bearing race location for reassembly reference. Components must be installed in original location.

14. On all models, remove drive pinion from differential carrier. Press rear bearing from drive pinion (if necessary). If drive pinion is damaged, replace drive pinion and ring gear as a set. Remove washer from drive pinion. Using hammer and brass drift, tap bearing races from differential carrier (if necessary).

NOTE:

Rear axle applications do not use lock plates on ring gear bolts.

15. Place reference mark on ring gear and differential case for reassembly reference. Bend over tabs on lock plates (if equipped) on ring gear bolts. Remove ring gear bolts/nuts. Using soft-faced hammer, tap ring gear from differential case.

16. Reinstall differential case with side bearings and races in differential case. Install side bearing caps and adjusting nuts. Tighten adjusting nuts until no play exists in side bearing. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS .

17. Using dial indictor, check differential case runout at ring gear mounting surface on differential case while rotating differential case. Replace differential case if runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS . Remove differential case and components from differential carrier.

Using puller, remove side bearings from differential case (if necessary).

NOTE:

Note components for each application before disassembling differential case. See Fig. 6 or Fig. 11 .

NOTE:

On rear axle applications, pinion shaft pin for pinion shaft is threaded into differential case. On all other models, pin is press fit in differential case.

18. On rear axle, unscrew pinion shaft pin for pinion shaft from differential case. On front axle, using a punch and hammer, remove straight pin from differential case.

19. Remove pinion shaft, side gears, pinion gears and thrust washers. See Fig. 6 .

20. Using soft-face hammer, separate differential cases. Remove pinion gears, side gears, thrust washers and spider. Using press, press out and discard dust deflector from companion flange.

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Fig. 9: Checking Companion Flange Lateral & Vertical Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 10: Checking Ring Gear Runout, Ring Gear Backlash & Side Gear Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Reassembly & Adjustments Microsoft Thursday, August 27, 2009 1:51:00 PM

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1. Using press, press NEW dust deflector on companion flange. Install side gears, pinion gears, thrust washers and pinion shaft in differential case. Ensure hole in pinion shaft aligns with hole for pin in differential case.

2. Recheck side gear backlash. Ensure side gear backlash is within specification. See AXLE ASSEMBLY SPECIFICATIONS .

3. If side gear backlash is not within specification, install different thickness thrust washers on side gears and recheck side gear backlash. Thrust washer is available in various thickness. Consult parts department for availability.

4. On rear axle, install and tighten pinion shaft pin for pinion shaft to specification. See TORQUE SPECIFICATIONS .

5. On all models, using press, install NEW side bearings on differential case (if removed). If installing ring gear, heat ring gear to 212°F (100°C) in boiling water.

6. Remove ring gear from water and allow moisture to evaporate. Install ring gear on differential case with reference marks aligned. Install lock plates (if equipped) on differential case.

NOTE:

Rear axle applications do not use lock plates on ring gear bolts and ring gear bolts MUST be installed so tapered edge of ring gear bolt is on teeth side of ring gear side.

7. Loosely install ring gear bolts to ensure bolt holes are aligned. Allow ring gear to cool.

CAUTION: DO NOT tighten ring gear bolts to specification until ring gear has cooled.

8. Once ring gear has cooled, install and tighten ring gear bolts in a crisscross pattern to specification. Bend tabs on lock plates (if equipped) against ring gear bolts.

9. Using dial indicator, check ring gear runout. See AXLE ASSEMBLY SPECIFICATIONS . On front axle applications, install NEW oil storage ring into differential carrier (if removed). Oil storage fits in front of differential carrier, below race of front drive pinion bearing.

10. Using press, install NEW races for front and rear bearings in differential carrier (if removed). If installing NEW rear bearing on drive pinion, install washer on drive pinion with chamfered side of washer toward teeth end of drive pinion. Press rear bearing on drive pinion.

11. Install drive pinion, front bearing and oil slinger in differential carrier. DO NOT install spacer and oil seal at this time.

12. Install drive pinion and front bearing in differential carrier. DO NOT install spacer, oil slinger and oil seal at this time.

13. Install companion flange on drive pinion. Coat threads of drive pinion nut with oil. Install washer (if equipped) and drive pinion nut on drive pinion.

14. Drive pinion nut will be tightened in small increments to obtain correct drive pinion rotating torque. Hold companion flange and slightly tighten drive pinion nut in small increments.

CAUTION: When tightening drive pinion nut, DO NOT overtighten nut, as spacer is not installed on drive pinion. Drive pinion nut must be tightened Microsoft Thursday, August 27, 2009 1:51:00 PM

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until correct drive pinion rotating torque is obtained.

15. Turn bearing clockwise and counterclockwise to set bearing. Using INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of drive pinion to determine drive pinion bearing preload for reassembly reference. Tighten drive pinion nut until correct drive pinion rotating torque is obtained. See AXLE ASSEMBLY SPECIFICATIONS .

16. Install bearing races on side bearings. Ensure bearing races are installed on original side bearings. Install differential case in differential carrier. Ensure backlash exists between ring gear and drive pinion.

17. Install adjusting nuts on differential carrier in original location. Ensure adjusting nuts are properly threaded into differential carrier.

18. Install side bearing caps in original location with reference marks aligned. Install side bearing cap bolts about 3 revolutions and press side bearing caps downward.

19. If side bearing caps do not seat tightly on differential carrier, adjusting nuts are not properly threaded into differential carrier. Remove adjusting nuts and reinstall (if necessary).

20. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS . Loosen side bearing cap bolts until side bearing cap bolts can be rotated by hand.

21. Fully tighten side bearing cap bolts by hand. Tighten adjusting nut on backside (opposite ring gear teeth) until ring gear has a backlash of about .008" (.20 mm).

22. While rotating ring gear, fully tighten adjusting nut on front side (teeth side of ring gear) to fully seat bearings. Loosen adjusting nut on front side (teeth side of ring gear).

23. Position dial indicator on differential carrier with stem resting against top of adjusting nut on backside (opposite ring gear teeth). Tighten adjusting nut on front side (teeth side of ring gear) until dial indicator starts to move.

24. Tighten adjusting nut on front side (teeth side of ring gear) an additional 1 to 1 1/2 notches. Notches on adjusting nut are openings that adjusting nut lock fits into.

25. Using dial indicator, check ring gear backlash. Ring gear backlash should be within specification.

26. If ring gear backlash is not within specification, rotate both adjusting nuts same amount. For example, if adjusting nut on front side (teeth side of ring gear) is loosened one notch, adjusting nut on backside (opposite ring gear teeth) must be tightened one notch. Ensure adjusting nuts are moved same amount to maintain proper bearing preload.

27. Once correct gear backlash is obtained, tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS. Recheck ring gear backlash.

28. Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear. Total assembled preload should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

29. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If gear tooth contact pattern is incorrect, change thickness of washer installed on drive pinion.

30. Remove drive pinion nut and washer (if equipped). Using puller, remove companion flange from drive pinion.

31. Remove front bearing and oil slinger from differential carrier. Remove front bearing.

32. Install NEW spacer on drive pinion. Install front bearing on drive pinion. Install oil slinger in original direction of installation.

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NOTE:

Ensure oil slinger is installed with concave side facing toward rear bearing.

33. Install NEW oil seal to correct depth on differential carrier. Correct depth is .039" (1.00 mm).

34. Apply grease on lip of oil seal. Install companion flange on drive pinion. Apply grease to threads of NEW drive pinion nut. Install washer and drive pinion nut on drive pinion.

35. Tighten drive pinion nut to MINIMUM specification. See TORQUE SPECIFICATIONS . Using INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of just drive pinion to determine drive pinion bearing preload. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

36. If drive pinion rotating torque exceeds specification, replace spacer and repeat procedure. If drive pinion rotating torque is less than specified, tighten drive pinion nut in small increments until correct rotating torque is obtained. DO NOT exceed MAXIMUM drive pinion nut torque. If maximum torque is exceeded, replace spacer and repeat procedure. DO NOT back off drive pinion nut.

37. Recheck ring gear backlash and gear tooth contact pattern. Using dial indicator, check vertical and lateral runout on companion flange while rotating companion flange. See Fig. 9 . If vertical or lateral runout exceeds .0039" (0.10 mm), check bearing on drive pinion.

38. Once all specifications are correct, stake drive pinion nut against drive pinion. Install adjusting nut lock on each adjusting nut. Install and tighten bolt to specification.

DIFFERENTIAL ASSEMBLY (4-PINION) Disassembly (Front)

1. Using dial indicator, check vertical and lateral runout on companion flange while rotating companion flange. See Fig. 9 . Replace companion flange if vertical or lateral runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS .

2. Using dial indicator, check ring gear runout at backside of ring gear while rotating ring gear. See Fig. 10 .

Replace ring gear and drive pinion as a set if ring gear runout exceeds specification.

3. Using dial indicator, check ring gear backlash while rotating ring gear back and forth while holding drive pinion from rotating. Ring gear backlash should be within specification. If ring gear backlash is not within specification, adjust side bearing preload or repair as necessary.

4. Using INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of just drive pinion to determine drive pinion bearing preload for reassembly reference. Drive pinion rotating torque should be within specification.

5. Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear for reassembly reference. Total assembled preload should be within specification.

6. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. 7. Remove bolt and Electronic Locking Differential (ELD) actuator from differential carrier. Remove "O" ring. Remove ELD indictor switch and gasket. Remove ELD screw plugs, spring seat, compression spring and ball.

8. Using punch and hammer, remove slotted spring pin. Remove bolts from shaft retainer and using a plastic Microsoft Thursday, August 27, 2009 1:51:00 PM

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9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

hammer, remove shaft retainer. Using a screwdriver, remove shift fork shaft.

Using hammer and chisel, loosen stake area on drive pinion nut. Remove drive pinion nut.

Using puller, remove companion flange from drive pinion. Using puller, remove oil seal from differential carrier.

Note direction of oil slinger installation. Remove oil slinger. Using puller, remove front bearing from drive pinion.

Place reference mark on side bearing caps and differential carrier for reassembly reference. Remove adjusting nut locks located on each side bearing cap. Remove side bearing caps. Remove differential case with side bearing outer races, adjusting nuts and sleeve. Remove shift fork.

Mark adjusting nut and side bearing race location for reassembly reference. Components must be installed in original location.

Remove drive pinion from differential carrier. Press rear bearing from drive pinion (if necessary).

Remove washer from drive pinion. If drive pinion or ring gear are damaged, replace them as a set. Using puller, remove front bearing race from differential carrier (if necessary).

Using hammer and brass drift, tap oil storage ring from differential carrier (if necessary). Using hammer and brass drift, tap rear bearing race from differential carrier (if necessary).

Place reference mark on ring gear and differential case for reassembly reference. Bend over tabs on lock plates on ring gear bolts (if equipped). Remove ring gear bolts/nuts. Using soft-faced hammer, tap ring gear from differential case.

Reinstall differential case with side bearings and races in differential case. Install side bearing caps and adjusting nuts. Tighten adjusting nuts until no play exists in side bearing. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS .

Using dial indictor, check differential case runout at ring gear mounting surface on differential case while rotating differential case. Replace differential case if runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS . Remove differential case and components from differential carrier.

On all models, using puller, remove side bearings from differential case (if necessary).

Place reference marks on differential cases for reassembly reference. See Fig. 11 . Remove differential case bolts uniformly, a little at a time.

Using soft-faced hammer, separate differential cases. Remove pinion gears, side gears, thrust washers and spider.

Install sleeve in left differential case and check that it slides freely. Using feeler gauge, measure clearance between shift fork and sleeve. See Fig. 12 . Clearance should be .006-.014" (0.15-0.36 mm). Using press, remove dust deflector from companion flange (if necessary).

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Fig. 11: Exploded View Of Typical 4-Pinion Type Differential Assembly With ELD (Front Shown; Rear Is Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Microsoft Thursday, August 27, 2009 1:51:01 PM

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Fig. 12: Measuring Clearance Between Shift Fork & Sleeve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Reassembly & Adjustments

1. Using press, press NEW dust deflector on companion flange (if removed). Install spider, side gears, pinion gears and thrust washers in right differential case. Using dial indicator, check side gear backlash in 4 locations, while holding one side gear against differential case. See Fig. 13 . Check side gear backlash in left and right differential cases.

2. Side gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS . If side gear backlash is not within specification, install different thickness thrust washer on both side gears and recheck side gear backlash. Thrust washer is available in various thickness. Consult parts department for availability.

3. Once correct side gear backlash is obtained, coat components with gear oil. Assemble right and left differential cases with reference mark aligned. Install and tighten bolts to specification. See TORQUE Microsoft Thursday, August 27, 2009 1:51:01 PM

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SPECIFICATIONS .

4. Using press, install NEW side bearings on differential case (if removed). If installing ring gear, heat ring gear to 212°F (100°C) in boiling water.

5. Remove ring gear from water and allow moisture to evaporate. Install ring gear on differential case with reference marks aligned. Install lock plates on differential case.

6. Loosely install all ring gear bolts to ensure bolt holes are aligned. Allow ring gear to cool.

CAUTION: DO NOT tighten ring gear bolts to specification until ring gear has cooled.

Fig. 13: Checking Side Gear Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Once ring gear has cooled, tighten ring gear bolts in a crisscross pattern to specification. Bend tabs on lock plates against ring gear bolts (if equipped).

8. Reinstall differential case with side bearings and races in differential case. Install side bearing caps and Microsoft Thursday, August 27, 2009 1:51:01 PM

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9.

10.

11.

12.

adjusting nuts. Tighten adjusting nuts until no play exists in side bearing. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS .

Using dial indictor, check ring gear runout wile rotating differential case. Replace ring gear and pinion gear if runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS . Remove differential case and components from differential carrier.

Using a hammer and brass drift, install NEW oil storage ring. Using press, install NEW races for front and rear bearings in differential carrier (if removed). If installing NEW rear bearing on drive pinion, install washer on drive pinion with chamfered side of washer toward teeth end of drive pinion. Press rear bearing on drive pinion.

Install drive pinion, front bearing and oil slinger in differential carrier. DO NOT install spacer and oil seal at this time.

Install companion flange on drive pinion. Coat threads of drive pinion nut with oil. Install washer (if equipped) and drive pinion nut on drive pinion. Hold companion flange and slightly tighten drive pinion nut in small increments.

CAUTION: When tightening drive pinion nut, DO NOT overtighten nut, as spacer is not installed on drive pinion. Drive pinion nut must be tightened until correct drive pinion rotating torque is obtained.

13. Turn drive pinion clockwise and counterclockwise several times. Using INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of drive pinion to determine drive pinion bearing preload for reassembly reference. Tighten drive pinion nut until correct drive pinion rotating torque is obtained. See AXLE ASSEMBLY SPECIFICATIONS .

14. Apply grease to shift fork rack and connecting part of indicator switch. Insert shift fork into differential carrier. Install bearing races on side bearings. Ensure bearing races are installed on original side bearings.

Install Adjusting nuts and left side sleeve. Ensure sleeve moves smoothly. Install differential case in differential carrier wile aligning shift fork in groove of sleeve. Ensure backlash exists between ring gear and drive pinion.

15. Install side bearing caps in original location with reference marks aligned. Install side bearing cap bolts about 3 revolutions and press side bearing caps downward.

16. If side bearing caps do not seat tightly on differential carrier, adjusting nuts are not properly threaded into differential carrier. Remove adjusting nuts and reinstall (if necessary).

17. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS . Loosen side bearing cap bolts until side bearing cap bolts can be rotated by hand.

18. Fully tighten side bearing cap bolts by hand. Tighten adjusting nut on backside (opposite ring gear teeth) until ring gear has a backlash of about .008" (0.20 mm).

19. While rotating ring gear, fully tighten adjusting nut on front side (teeth side of ring gear) to fully seat bearings. Loosen adjusting nut on front side (teeth side of ring gear).

20. Position dial indicator on differential carrier with stem resting against top of adjusting nut on backside (opposite ring gear teeth). Tighten adjusting nut on front side (teeth side of ring gear) until dial indicator starts to move.

21. Tighten adjusting nut on front side (teeth side of ring gear) an additional 1 to 1 1/2 notches. Notches on adjusting nut are openings that adjusting nut lock fits into.

22. Using dial indicator, check ring gear backlash. Ring gear backlash should be within specification.

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23. If ring gear backlash is not within specification, rotate both adjusting nuts same amount. For example, if adjusting nut on front side (teeth side of ring gear) is loosened one notch, adjusting nut on backside (opposite ring gear teeth) must be tightened one notch. Ensure adjusting nuts are moved same amount to maintain proper bearing preload.

24. Once correct gear backlash is obtained, tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS . Recheck ring gear backlash.

25. Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear. Total assembled preload should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

26. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If gear tooth contact pattern is incorrect, change thickness of washer installed on drive pinion.

27. Remove drive pinion nut and washer (if equipped). Using puller, remove companion flange from drive pinion. Remove front bearing and oil slinger from differential carrier.

28. Install NEW spacer on drive pinion. Install front bearing on drive pinion. Install oil slinger in original direction of installation.

NOTE:

Ensure oil slinger is installed with concave side facing toward rear bearing.

29. Install NEW oil seal to correct depth on differential carrier. Correct depth is .039" (1.00 mm).

30. Apply grease on lip of oil seal. Install companion flange on drive pinion. Apply grease to threads of NEW drive pinion nut. Install washer and drive pinion nut on drive pinion.

31. Tighten drive pinion nut to MINIMUM specification. See TORQUE SPECIFICATIONS . Using INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of just drive pinion to determine drive pinion bearing preload. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

32. If drive pinion rotating torque exceeds specification, replace spacer and repeat procedure. If drive pinion rotating torque is less than specified, tighten drive pinion nut in small increments until correct rotating torque is obtained. DO NOT exceed MAXIMUM drive pinion nut torque. If maximum torque is exceeded, replace spacer and repeat procedure. DO NOT back off drive pinion nut.

33. Recheck ring gear backlash and gear tooth contact pattern. Using dial indicator, check vertical and lateral runout on companion flange while rotating companion flange. See Fig. 9 . If vertical or lateral runout exceeds .0039" (0.10 mm), check bearing on drive pinion.

34. Once all specifications are correct, stake drive pinion nut against drive pinion. Install adjusting nut lock on each adjusting nut. Install and tighten nut to specification.

35. Apply grease to fork shaft. Install fork shaft. Align fork shaft screw plug holes with holes on shift fork.

Place a bead of RTV sealant to shaft retainer as illustrated. See Fig. 14 . Apply adhesive to bolt threads and install shaft retainer bolts.

36. Using a punch and hammer, install slotted spring pin in to shift lock. Push shift fork in to lock position.

See Fig. 15 . Install ball, compression spring and spring seat. Apply adhesive to screw plug and install plug.

37. Measure distance between sleeve and tip of differential case when differential is in free and locked Microsoft Thursday, August 27, 2009 1:51:01 PM

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