1996 TOYOTA LAND CRUISER differential

Z15220
FIPG Width Approx.
1 − 2 mm (0.04 − 0.08 in.)
Z07262Adhesive
SA2620
SA−11 0
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
1996 LAND CRUISER (RM451U)
(g) Connect the connector and tube.
HINT:
The depth of the insertion of the bleeder tube into the
hose is approx. 15 mm (0.59 in.).
Take care that water or the equivalent will not adhere to
the connector and hose.
(h) Cancel the front differential lock.
With the ignition switch ON, turn the differential lock con-
trol switch to OFF to cancel the differential lock.
2. INSTALL REAR ACTUATOR
(a) Clean contacting surfaces of any FIPG material using gasoline or alcohol.
(b) Apply FIPG to the actuator. FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
HINT:
Install the actuator within 10 minutes after applying FIPG.
(c) Install the actuator to the differential and match the shaft with the shaft fork hole.
(d) Clean the threads of the set bolt and shaft fork with the white gasoline.
(e) Coat the threads of the set bolt with adhesive.
Adhesive: Part No. 08833 −00070, THREE BOND 1324
or equivalent
(f) Tighten the shift fork set bolt. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(g) Tighten the 4 bolts uniformly, a little at a time. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(h) Install the cover. (1) Clean the contacting surfaces of any FIPG material
using gasoline or alcohol.
(2) Apply FIPG to the cover.
FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
HINT:
Install the cover within 10 minutes after applying FIPG.
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SA2619
Z07261
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
SA−111
1996 LAND CRUISER (RM451U)
(3) Tighten the 3 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(i) Install the rear Diff. position switch. Install the position switch with a new gasket.
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
(j) Connect the connectors and tube.
HINT:
The depth of the insertion of the bleeder tube into the
hose is approx. 15 mm (0.59 in.).
Take care that the water or the equivalent will not adhere
to the connectors and hose.
(k) Install the actuator protector. Install the protector with the 2 nuts and bolt.
Torque:
Nut: 35 N·m (360 kgf·cm, 26 ft·lbf)
Bolt: 20 N·m (200 kgf·cm, 14 ft·lbf)
(l) Cancel the rear differential lock. With the ignition switch ON, turn the differential lock con-
trol switch to OFF to cancel the differential lock.
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SS−8
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1996 LAND CRUISER (RM451U)
A/C compressor bracket x No. 1 oil pan
3737527
A/C compressor bracket x Cylinder block3737527
A/C compressor x A/C compressor bracket2525018
Oil check valve x Cylinder block2525018
Main bearing cap x Cylinder block
1st
2nd74
Turn 90°750
Turn 90°54
Turn 90°
Connecting rod cap x Connecting rod 1st
2nd48
Turn 90°490
Turn 90°35
Turn 90°
Rear oil seal retainer x Cylinder block2121015
Oil cooler cover x Cylinder block2121015
LH engine mounting bracket x Cylinder block6970051
LH insulator x LH engine mounting bracket7273043
RH engine mounting bracket x Cylinder brock6970051
RH insulator x RH engine mounting bracket7273043
PS pump x Cylinder block3637027
Knock sensor x Cylinder block4445033
Oil filter union x Cylinder block4445033
Drive plate x Crankshaft1001,00074
Transmission x Cylinder block7273053
Transmission x No. 1 oil pan7273053
Torque converter clutch x Drive plate5555041
A/T oil cooler pipe x Union (Transmission)3435025
Starter x Transmission3940029
Frame crossmember x Frame6162045
Frame crossmember x Engine rear mounting insulator7475054
Engine front mounting insulator x Frame7475054
Transfer shift lever x Transmission1818513
Transmission shift lever assembly x Body5.45548 in.·lbf
Transmission control rod x Control shaft lever131309
Front propeller shaft x Front dif ferential7475054
Front propeller shaft x Transfer7475054
Rear propeller shaft x Rear differential8890065
Rear propeller shaft x Transfer8890065
Stabillizer bar bracket mounting bolt1818513
Stabillizer bar x Axle carrier2526019
PS pressure hose x PS pump5657542
Rear TWC x Center pipe4040029
Center pipe x Tailpipe4040029
Heated oxygen sensor (Bank 1 sensor 1) x Front exhaust pipe2020014
Heated oxygen sensor (Bank 1 sensor 2) x Center pipe2020014
No. 2 support bracket x Frame18.518513
No. 3 support bracket x Frame18.518513
No. 4 support bracket x Frame18.518513
Exhaust pipe damper x Tailpipe19.519514
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SS1E8−02
−
SERVICE SPECIFICATIONS TRANSFER
SS−25
148
Author: Date:
1996 LAND CRUISER (RM451U)
TRANSFER
SERVICE DATA
Idler gear rear bearing adjusting shim thickness Mark 2
3
4
5
6
7
8
9
10 11
12
130.30 mm (0.0118 in.)
0.45 mm (0.0177 in.)
2.40 mm (0.0945 in.)
2.60 mm (0.1024 in.)
2.80 mm (0.1102 in.)
3.00 mm (0.1181 in.)
3.20 mm (0.1260 in.)
3.40 mm (0.1339 in.)
3.60 mm (0.1417 in.)
3.80 mm (0.1496 in.)
4.00 mm (0.1575 in.)
0.55 mm (0.0216 in.)
Output shaft rear bearing adjusting shim thickness Mark B
C
DEF
G H J
K L
M N0.30 mm (0.0118 in.)
0.45 mm (0.0177 in.)
1.00 mm (0.0394 in.)
1.20 mm (0.0472 in.)
1.40 mm (0.0551 in.)
1.60 mm (0.0630 in.)
1.80 mm (0.0709 in.)
2.00 mm (0.0787 in.)
2.20 mm (0.0866 in.)
2.40 mm (0.0945 in.)
2.60 mm (0.1024 in.)
0.55 mm (0.0216 in.)
Input gear snap ring thickness Mark A
B
C
D E
F
G H J2.00 mm (0.0787 in.)
2.10 mm (0.0827 in.)
2.20 mm (0.0866 in.)
2.30 mm (0.0906 in.)
2.40 mm (0.0945 in.)
2.50 mm (0.0984 in.)
2.60 mm (0.1024 in.)
2.70 mm (0.1063 in.)
2.80 mm (0.1102 in.)
Input shaft rear ball bearing snap ring thickness Mark A
B
C
D E2.00 mm (0.0787 in.)
2.10 mm (0.0827 in.)
2.20 mm (0.0866 in.)
2.30 mm (0.0906 in.)
2.40 mm (0.0945 in.)
Idler low gear thrust clearance STD
Max.0.125 − 0.275 mm (0.0049 − 0.0108 in.)
0.275 mm (0.0108 in.)
Idler low gear radial clearance STD
Max.0.015 − 0.068 mm (0.0006 − 0.0027 in.)
0.068 mm (0.0027 in.)
High speed output gear thrust clearance STD
Max.0.10 − 0.25 mm (0.0039 − 0.0098 in.)
0.25 mm (0.0098 in.)
High speed output gear radial clearance STD
Max.0.015 − 0.071 mm (0.0006 − 0.0028 in.)
0.071 mm (0.0028 in.)
Center differential backlash Min.0.05 mm (0.0020 in.)
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SS−26
−
SERVICE SPECIFICATIONS TRANSFER
149
Author: Date:
1996 LAND CRUISER (RM451U)
Center differential side gear thrust washer thickness
1.70 mm (0.0669 in.)
1.85 mm (0.0728 in.)
2.00 mm (0.0787 in.)
2.15 mm (0.0846 in.)
2.30 mm (0.0906 in.)
2.45 mm (0.0965 in.)
2.60 mm (0.1024 in.)
2.75 mm (0.1083 in.)
2.90 mm (0.1142 in.)
3.05 mm (0.1201 in.)
Front drive gear piece snap ring thickness
Mark A
B
C
D E
F
G H J
K
L2.00 mm (0.0787 in.)
2.10 mm (0.0827 in.)
2.20 mm (0.0866 in.)
2.30 mm (0.0906 in.)
2.40 mm (0.0945 in.)
2.50 mm (0.0984 in.)
2.60 mm (0.1024 in.)
2.70 mm (0.1063 in.)
2.80 mm (0.1102 in.)
1.80 mm (0.0709 in.)
1.90 mm (0.0748 in.)
Front extension housing ball bearing snap ring thickness Mark A
B1.7 mm (0.0669 in.)
1.8 mm (0.0709 in.)
Front output shaft hub snap ring thickness Mark A
B
C
D E1.8 mm (0.0709 in.)
1.9 mm (0.0748 in.)
2.0 mm (0.0787 in.)
2.1 mm (0.0827 in.)
2.2 mm (0.0866 in.)
Oil pump driven rotor body clearance STD
Max.0.08 − 0.17 mm (0.0031 − 0.0067 in.)
0.17 mm (0.0067 in.)
Oil pump driven rotor body tip clearance STD
Max.0.05 − 0.15 mm (0.0020 − 0.0059 in.)
0.15 mm (0.0059 in.)
Oil pump side clearance STD
Max.0.03 − 0.10 mm (0.0012 − 0.0039 in.)
0.10 mm (0.0039 in.)
Rear extension housing ball bearing snap ring thickness Mark A
B1.7 mm (0.0669 in.)
1.8 mm (0.0709 in.)
Rear output shaft ball bearing snap ring thickness Mark 1
2
3
41.95 mm (0.0768 in.)
2.05 mm (0.0807 in.)
2.15 mm (0.0847 in.)
2.25 mm (0.0886 in.)
Motor actuator
Terminal 2 − Terminal 3 STD resistance
Terminal 2 or 3 − Body ground STD resistance
0.3 − 100 Ω
More than 0.5 MΩ
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SS1E9−02
−
SERVICE SPECIFICATIONS TRANSFER
SS−27
1996 LAND CRUISER (RM451U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Oil pump plate and separator x Rear extension housing4.95043 in.·lbf
Oil pump cover x Rear extension housing4.95043 in.·lbf
Lever lock pin121209
Oil strainer x Rear case4.95043 in.·lbf
Oil receiver x Front case121209
Case cover x Rear case3738027
Rear extension housing x Rear case3738027
Front extension housing x Front case3738027
Center differential lock Indicator switch3738014
L4 position switch3738027
Neutral position switch3738027
Screw plug x Front case1919014
Screw plug x Rear extension housing2930022
Motor actuator x Front case1818513
Differential front case x Differential rear case
Temporarily tighten98
881,00090072
65
Front case x Rear case3738027
Rear case x Retainer3940028
Dynamic damper x Rear extension housing3738027
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SS1EB−01
−
SERVICE SPECIFICATIONS PROPELLER SHAFT
SS−29
1996 LAND CRUISER (RM451U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Front propeller shaft x Front dif ferential7475054
Front propeller shaft x Transfer7475054
Rear propeller shaft x Rear differential8890065
Rear propeller shaft x Transfer8890065
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SS−32
−
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
155
Author: Date:
1996 LAND CRUISER (RM451U)
Rear dif
ferential
(cont’d)
Side bearing adjusting plate thickness
(w/ Differential lock only)2.67 mm (0.1051 in.)
2.70 mm (0.1063 in.)
2.73 mm (0.1075 in.)
2.76 mm (0.1087 in.)
2.79 mm (0.1098 in.)
2.82 mm (0.1110 in.)
2.85 mm (0.1122 in.)
2.88 mm (0.1134 in.)
2.91 mm (0.1146 in.)
2.94 mm (0.1157 in.)
2.97 mm (0.1169 in.)
3.00 mm (0.1181 in.)
3.03 mm (0.1193 in.)
3.06 mm (0.1205 in.)
3.09 mm (0.1217 in.)
3.12 mm (0.1228 in.)
3.15 mm (0.1240 in.)
3.18 mm (0.1252 in.)
3.21 mm (0.1264 in.)
3.24 mm (0.1276 in.)
3.27 mm (0.1287 in.)
3.30 mm (0.1299 in.)
3.33 mm (0.1311 in.)
Rear axleRear axle shaft runout Max.
Distance between top surface of axle housing and lock nut0.8 mm (0.031 in.)
− 0.2 − 0.9 mm (− 0.0079 − 0.0354 in.)
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