1996 TOYOTA LAND CRUISER Workshop Manual

R13166
SST
SA2348
SST
Z00641
SST
SSTSST
SA−82
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
(c) Using SST, remove the companion flange.
SST 09950 −30010 (09951 −03010, 09953 −03010,
09954 −03010, 09955 −03030, 09956−03020)
12. REMOVE OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal from the dif ferential carrier.
SST 09308−10010
(b) Remove the oil slinger.
13. REMOVE FRONT BEARING
Using SST, remove the front bearing from the drive pinion. SST 09556−22010
If the front bearing is damaged or worn, replace the bearing.
14. w/o DIFFERENTIAL LOCK: REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Place matchmarks on the bearing cap and dif ferential car-
rier.
(b) Remove the 2 adjusting nut locks.
HINT:
Tag the disassembled parts to show the location for reassemb-
ly.
(c) Remove the 2 bearing caps and adjusting nuts.
(d) Remove the differential case with the bearing outer races
from the carrier.
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SA2437Matchmarks
R08254
SST
Z06911
SST
SA2424
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−83
1996 LAND CRUISER (RM451U)
15. w/ DIFFERENTIAL LOCK:
REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Place matchmarks on the bearing cap and dif ferential car-
rier.
(b) Remove the 4 bolts and 2 bearing caps.
(c) Using SST, remove the plate washers. SST 09504−22011
HINT:
Measure the plate washer thickness and note it.
(d) Remove the differential case with the side bearing outer races from the differential carrier.
HINT:
Tag the bearing outer races to show the location for reassembly.
16. REMOVE DRIVE PINION AND BEARING SPACER FROM DIFFERENTIAL CARRIER
(a) Remove the drive pinion with the rear bearing.
(b) Remove the bearing spacer.
17. REMOVE DRIVE PINION REAR BEARING
(a) Using SST and a press, remove the rear bearing from the
drive pinion.
SST 09950−00020
HINT:
If the drive pinion or ring gear are damaged, replace them as
a set.
(b) Remove the plate washer from the drive pinion.
18. REMOVE FRONT AND REAR BEARING OUTER
RACES
Using a brass bar and hammer, remove the outer races.
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SA2464
SA−84
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
19. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 ring gear set nuts and bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the differential case.
20. CHECK DIFFERENTIAL CASE RUNOUT
(a) Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in
the bearing.
(b) Using a dial indicator, measure the differential case run- out.
Maximum case runout: 0.07 mm (0.0028 in.)
(c) Remove the differential case.
21. w/o DIFFERENTIAL LOCK: REMOVE SIDE BEARINGS FROM DIFFERENTIAL
CASE
Using SST, remove the 2 side bearings from the differential
case. SST 09950 −40010 (09951 −04010, 09952 −04010,
09953 −04020, 09955 −04060, 09957 −04010,
09958 −04010), 09950−60010 (09951 −00480)
22. w/ DIFFERENTIAL LOCK:
REMOVE SIDE BEARINGS FROM DIFFERENTIAL
CASE
(a) Using SST, remove the side bearing (ring gear side). SST 09950 −40010 (09951 −04010, 09952 −04010,
09953 −04020, 09955 −04060, 09957 −04010,
09958 −04010), 09950−60010 (09951 −00480)
HINT:
Fix the claws of SST to the notches in the differential case.
(b) Using SST, 4 bolts and a press, remove the side bearing (cover side).
SST 09550−10012 (09557 −10010),
09950 −70010 (09951 −07150)
HINT:
Fix the claws of SST to the notches in the differential case.
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SA2475
SST
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−85
1996 LAND CRUISER (RM451U)
23. w/o DIFFERENTIAL LOCK:
DISASSEMBLE DIFFERENTIAL CASE
(a) Remove the pinion shaft pin and washer.
(b) Remove these parts from the differential case:
Pinion shaft
2 Pinion gears
2 Pinion gear thrust washers
2 Side gears
2 Side gear thrust washers
24. w/ DIFFERENTIAL LOCK: DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the case and cover.
(b) Using a torx socket wrench, remove the 5 set bolts and 3
pinion shaft pins.
(c) Using the 2 cover installation bolts, separate the cover and case.
(d) Remove these parts from the differential case:
2 Side gears
2 Side gear thrust washers
4 Pinion gears
4 Pinion thrust washers
3 Pinion shafts
Pinion shaft holder
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SA1VI−01
SA2419
SST
SA2418SST
SA−86
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REMOVE DUST DEFLECTOR
Using SST and a press, remove the dust deflector. SST 09950−00020
2. INSTALL DUST DEFLECTOR
Using SST and a press, install a new dust deflector. SST 09726−40010
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SA0510
SA1VJ−04
Z06893
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−87
1996 LAND CRUISER (RM451U)
REASSEMBLY
1. w/o DIFFERENTIAL LOCK:
ASSEMBLE DIFFERENTIAL CASE
(a) Apply all of the sliding and rotating surfaces 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.
Backlash: 0.02 − 0.20 mm (0.0008−0.0079 in.)
Thrust washer thickness
Thickness mm (in.)Thickness mm (in.)
1.60 (0.063)1.90 (0.075)
1.75 (0.069)2.05 (0.081)
(c) Install the side gears with the side gear thrust washers,
pinion gears, pinion gear thrust washers and pinion shaft.
HINT:
Align the hole for the pinion shaft and differential case hole.
(d) Using a dial indicator, measure the side gear backlash with holding the one pinion gear toward the case.
Backlash: 0.02 − 0.20 mm (0.0008 − 0.0079 in.)
If the backlash is not within the specification, install a thrust
washer of different thickness.
(e) Install the pinion shaft pin and washer.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
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SA0510
R08274
R08276
R13246
SA−88
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
2. w/ DIFFERENTIAL LOCK:
MEASURE SIDE GEAR BACKLASH
(a) Apply all of the sliding and rotating surfaces with gear oil.
(b) Install the thrust washer to the side gear.
(c) Install the thrust washer to the pinion gear.
(d) Install the side gear into the case.
(e) Install the holder into the case.
(f) Install the 4 pinion gears with the thrust washers.
(g) Align the pinion shaft hole and case pinion shaft pin hole,
and install the pinion shaft.
(h) Install the side gear to the cover.
(i) Align the matchmarks and install the case and cover.
(j) Using a torx socket wrench, torque the 5 bolts and 3 pin-
ion shaft pins.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(k) Using a dial indicator, with holding the side gear and mea- sure the backlash.
Backlash: 0.02 − 0.20 mm (0.0008 − 0.0079 in.)
HINT:
Measure at all 4 locations.
If the backlash is not within the specification, install the thrust
washer of a different thickness. Thrust washer thickness
Thickness mm (in.)Thickness mm (in.)
1.60 (0.063)1.90 (0.075)
1.75 (0.069)2.05 (0.081)
(l) After measuring backlash, remove the 5 set bolts and 3pinion shaft pins.
3. w/ DIFFERENTIAL LOCK: ASSEMBLE DIFFERENTIAL CASE
(a) Clean the thread of the bolts, pinion shaft pins, case and
cover with the white gasoline.
(b) Coat the threads of the bolts and pinion shaft pins with adhesive.
Adhesive: Part No. 08833 −00070, THREE BOND 1324
or equivalent
(c) Align the matchmarks, install the case and cover.
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SA1143
Boiling Water
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−89
1996 LAND CRUISER (RM451U)
(d) Using a torx socket wrench, torque the 5 bolts and 3 pin-
ion shaft pins.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
4. INSTALL SIDE BEARINGS
(a) w/o Differential lock: Using SST and a press, install the 2 side bearings on the
differential case.
SST 09315−00022, 09550 −10012 (09558−10010)
(b) w/ Differential lock:
Using SST and a press, install the 2 side bearings on the
differential case.
SST 09550−60010, 09550 −10012 (09558−10010)
5. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and ring gear.
(b) Heat the ring gear to about 100° C (212°F) in boiling wa-
ter.
(c) Carefully remove the ring gear from the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(e) Align the matchmarks on the ring gear and differential case.
(f) Temporarily install the set bolts and nuts so that the bolt
holes in the ring gear and differential case are not misa-
ligned.
NOTICE:
Install the bolts so that the tapered part of the bolt is on the
ring gear side. The ring gear set nuts should not tighten un-
til the ring gear has cooled sufficiently.
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