Page 1088 of 1399
W00530
w/o Differential LockSide Gear Thrust WasherPinion Gear
Pinion Gear Thrust Washer
Dust Deflector
Front Bearing Outer Race
Oil Seal
Companion Flange
Bearing Cap
Differential Carrier
Adjusting Nut Lock Oil Slinger
Differential Case
Drive Pinion
Ring Gear
Side Baring
Straight Pin
Adjusting Nut
Bearing Spacer
Oil Storage Ring
Outer Race
Outer Race
Non− reusable part
Lock Plate
x 10
x 5 Pinion Shaft
Pinion Gear
Pinion Washer
Rear Bearing
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−25
882
Author: Date:
1996 LAND CRUISER (RM451U)
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Page 1089 of 1399
W00531
w/ Differential LockSide Gear
Thrust Washer
Pinion Gear
Thrust Washer
Outer Race
Oil Seal Companion Flange
Bearing Cap
Differential Carrier
Adjusting Nut Lock Oil Slinger
Drive Pinion
Ring Gear
Side Baring
Adjusting Nut
Bearing Spacer
Oil Storage Ring
Outer Race
Non− reusable part
Lock Plate x 8
x 4
O− Ring
Pinion Washer
Rear Bearing
Dust Deflector
Front Bearing Outer Race
Adjusting Nut
Sleeve
Spider Side GearLH Differential Case
RH Differential Case
x 8
Precoated part
Gasket Indicator Switch
Actuator
Straight Screw Plug
Spring Seat
Compression Spring
Ball
Shaft Retainer Shift Fork Shaft Shift Fork
Slotted Spring Pin
Pinion Gear
SA−26
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
883
Author: Date:
1996 LAND CRUISER (RM451U)
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Page 1090 of 1399
SA1UM−03
FA2038
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−27
1996 LAND CRUISER (RM451U)
REMOVAL
1. w/ DIFFERENTIAL LOCK:
BEFORE REMOVAL, SHIFT FRONT DIFFERENTIAL
TO LOCK
(a) Turn the ignition switch to the ON position.
(b) Keep the center differential lock condition.
(c) Turn the differential lock control switch to the FR/RR posi-
tion and lock the front differential.
(d) Rotating the tires, check they are in the differential lock condition.
(e) Disconnect the cable from the negative terminal of the battery.
2. DRAIN DIFFERENTIAL OIL
3. REMOVE FRONT AXLE SHAFTS (See page SA−13)
4. REMOVE TIE ROD FROM KNUCKLE ARM (See page SA−13 )
5. REMOVE FRONT PROPELLER SHAFT (See page PR−3 )
6. w/ DIFFERENTIAL LOCK: DISCONNECT CONNECTORS AND TUBE
HINT:
When connecting the tube of the harness side to the hose
of the actuator side, its depth of insertion is 15 mm (0.59
in.).
Take care that water or equivalent does not adhere to the
connector and hose.
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W00493
30 mm
(1.18 in.)
SA1UN−03
SA2465
SA2462
SA2403
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−29
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the vertical and lateral runout of
the companion flange. Maximum runout: 0.10 mm (0.0039 in.)
2. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout. Maximum runout: 0.10 mm (0.0039 in.)
If the runout is greater than the maximum, replace the ring gear
and driven pinion as a set.
3. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 −0.18 mm (0.0051 −0.0071 in.)
If the backlash is not within the specification, adjust the side
bearing preload or repair as necessary.
4. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of backlash be-
tween the drive pinion and ring gear. Preload (at starting):
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
5. CHECK TOTAL PRELOAD
Using a torque wrench, measure the preload. Total preload (at starting):
Drive pinion preload plus
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
If necessary, disassemble and inspect the differential.
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SA2442
R13332
SA2206
Z10098
SA−30
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
6. w/o DIFFERENTIAL LOCK:
CHECK SIDE GEAR BACKLASH
Using a dial indicator, measure the side gear backlash with
holding one pinion gear toward the case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washers (See page .SA−35 ).
7. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See page SA−35 )
8. w/ DIFFERENTIAL LOCK: REMOVE ACTUATOR
(a) Remove the bolt and actuator from the differential carrier.
(b) Remove the O−ring.
9. w/ DIFFERENTIAL LOCK: REMOVE INDICATOR SWITCH
Remove the indicator switch and gasket.
10. w/ DIFFERENTIAL LOCK:
REMOVE SHIFT FORK SHAFT
(a) Using a hexagon wrench, remove the 2 straight screw plugs.
(b) Remove the spring seat, compression spring and ball.
(c) Using a pin punch and hammer , remove the slotted spring
pin.
(d) Remove the 2 bolts from the shaft retainer.
(e) Using a plastic hammer, tap out the shaft retainer.
(f) Remove the shift fork shaft.
HINT:
Pull out the shift fork shaft with a screwdriver turned round.
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SA1UO−01
SA2419
SST
SA2418
SST
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−35
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REMOVE DUST DEFLECTOR TO COMPANION
FLANGE
Using SST and a press, remove the dust deflector. SST 09950−00020
2. INSTALL DUST DEFLECTOR TO COMPANION FLANGE
Using SST and a press, install a new dust deflector. SST 09726−40010
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Page 1099 of 1399
SA0510
SA1UP−03
Z06893
Z06894
R08149
SA−36
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
REASSEMBLY
1. w/o DIFFERENTIAL LOCK: ASSEMBLE DIFFERENTIAL CASE
(a) Apply all of the sliding and rotating sufaces with gear oil.
(b) Install the 2 thrust washers and side gears. Using the table below, select the thrust washers which will
ensure that the backlash is within the specification.
Try to select washers of the same size for both sides.
Thrust washer thickness
Thickness mm (in.)Thickness mm (in.)
1.60 (0.063).80 (0.071)
1.70 (0.067)1−
(c) Install the 2 side gears with the side gears thrust washers,
4 pinion gears, pinion gear thrust washers and pinion
shaft.
HINT:
Align the hole for the pinion shaft with the case hole.
(d) Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install a thrust
washer of different thickness.
(e) Using a pin punch and hammer, install the straight pin through the holes in the dif ferential case and pinion shaft.
(f) Using a chisel and hammer, stake the out side of the dif- ferential case pin hole.
2. w/ DIFFERENTIAL LOCK: INSPECT SLEEVE
(a) Install the sleeve to the differential case (LH) and check
it moves smoothly.
(b) Install the sleeve to the side gear check it moves smooth-
ly.
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Page 1103 of 1399
SA2401
SST
SA2403
SA2161
MP Grease
Z10100
SA−40
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
(c) Adjust the drive pinion preload by tightening the compan-
ion flange nut.
Using SST to hold the flange, tighten the nut.
SST 09330−00021
NOTICE:
As there is no spacer, tighten a little at a time, being careful
not to overtighten.
(d) Using a torque wrench, measure the preload. Preload (at starting):
New bearing
0.9 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
HINT:
Measure the total preload after first turning the bearing clock-
wise and counterclockwise several times to mark the bearing
smooth.
12. w/o DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the bearing outer races on their respective bear- ings. Make sure the left and right outer races are not inter-
changed.
(b) Install the case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
13. w/ DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Apply MP grease on the rack of the shift fork and connect- ing part of the indicator switch.
(b) Insert the shift fork into the differential carrier, as shown.
(c) Install outer races, adjusting nuts and left side to sleeve.
HINT:
Check that the sleeve moves smoothly.
(d) Install the shift fork in the groove of the sleeve holding it by hand and install the case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
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