1996 TOYOTA LAND CRUISER Land Cruiser 80

TR0BA−01
TF0893
SST
Q00538
TF0896
SST
−
TRANSFER IDLER GEAR
TR−17
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL FRONT TAPER ROLLER BEARING
Using SST and a press, install the front taper roller bearing.
SST 09316−60011 (09316 −00011, 09316−00031)
2. INSTALL HIGH AND LOW CLUTCH SLEEVE
HINT:
Make sure to install the high and low clutch sleeve in the correct
direction.
3. INSTALL NEEDLE ROLLER BEARING AND IDLER LOW GEAR TO IDLER GEAR
(a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing and idler low gear.
4. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing. SST 09316−60011 (09316 −00011, 09316−00071)
5. INSPECT IDLER LOW GEAR RADIAL AND THRUST CLEARANCE
(See page TR−16 )
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TR0BB−01
Q07134
Front Drive Gear
PieceHigh
Speed Output GearHigh Speed Output
Gear Bushing
Clutch HubHigh and Low
Clutch Sleeve Rear Taper Roller
Bearing
 Snap Ring
Needle Roller Bearing
Thrust Washer
Thrust Washer Rear Side Gear
Straight Pin x 12
Differential Rear Case
Thrust Washer
Pinion
Gear
Pinion Shaft
Front Side Gear
Thrust Washer
Differential Front Case
 Non− reusable part Low Gear
Straight Pin

Snap Ring Front T
aper Roller BearingNeedle Roller Bearing
Pinion Gear
TR−18
−
TRANSFER CENTER DIFFERENTIAL
828
Author: Date:
1996 LAND CRUISER (RM451U)
CENTER DIFFERENTIAL
COMPONENTS
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TR0BC−01
TF0900
TF0944
Q07101
SST
Q07102
SST
Q07103
SST
−
TRANSFER CENTER DIFFERENTIAL
TR−19
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND
THRUST CLEARANCE
(a) Using a feeler gauge, measure the high speed output gear thrust clearance.
Standard clearance:
0.10−0.25 mm (0.0039 −0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)
(b) Using a dial indicator, measure the high speed output gear radial clearance.
Standard clearance:
0.035−0.091 mm (0.0014 −0.0036 in.)
Maximum clearance:
0.091 mm (0.0036 in.)
2. REMOVE FRONT DRIVE GEAR PIECE
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the front drive gear piece.
SST 09950−00020, 09950 −60010 (09951−00320)
NOTICE:
Be careful not to drop the center differential assembly.
3. REMOVE FRONT TAPER ROLLER BEARING
Using SST and a press, remove the front taper roller bearing.
SST 09950−00020
4. REMOVE HIGH SPEED OUTPUT GEAR
5. REMOVE NEEDLE ROLLER BEARING
6. REMOVE HIGH AND LOW CLUTCH SLEEVE AS-
SEMBLY
7. REMOVE HIGH SPEED OUTPUT GEAR BUSHING AND CLUTCH HUB
(a) Using SST and a press, remove the high speed output
gear bushing and clutch hub.
SST 09550−00020, 09950 −00030, 09950−60010
(09951 −00320)
(b) Using a magnetic finger, remove the straight pin from the
differential front case.
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Q07113
SST
Q07114
SST
SST
Bearing
TR−20
−
TRANSFER CENTER DIFFERENTIAL
1996 LAND CRUISER (RM451U)
8. REMOVE REAR TAPER ROLLER BEARING
Using SST and a press, remove the rear taper roller bearing.
SST 09950−00020, 09950 −60010 (09951−00320)
9. REMOVE DIFFERENTIAL REAR CASE
Remove the 12 bolts and differential rear case.
10. REMOVE REAR SIDE GEAR AND THRUST WASHER
11. REMOVE PINION SHAFT, PINION GEAR AND THRUST
WASHER
(a) Remove the straight pin from the pinion shaft.
(b) Remove the pinion shaft, 2 pinion gears and thrust wash-
ers.
(c) Remove the front side gear and thrust washer.
12. REMOVE LOW GEAR
Using a plastic hammer, tap and remove the low gear.
NOTICE:
Be careful not to damage the low gear.
13. REMOVE NEEDLE ROLLER BEARING
(a) Using a screwdriver, remove the snap ring.
(b) Using SST and a hammer, remove the needle roller bear-
ing from the differential rear case.
SST 09223 −00010, 09950 −60010 (09951 −00400),
09950 −70010 (09951 −07150)
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TR0BD−01
Q07115
SSTStamp
TF1012
TF0913
TF0917
−
TRANSFER CENTER DIFFERENTIAL
TR−21
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing
to the differential rear case.
SST 09612−24014 (09612 −10050)
HINT:
Install the bearing to the differential rear case, taking care that
its stamped side comes in contact with SST.
(b) Install the snap ring.
2. INSTALL LOW GEAR
(a) Clean the contact surface of the differential case.
(b) Heat the low gear in boiling water.
(c) Carefully remove the low gear from the water.
(d) After the moisture on the low gear has completely evapo- rated, quickly install the low gear to the differential case.
3. INSTALL PINION SHAFT, PINION GEAR AND THRUST
WASHER
(a) Install the front side gear and thrust washer to the differ- ential front case.
(b) Install the pinion shaft, 2 pinion gears and thrust washers
to the differential front case.
(c) Using a dial indicator, measure the front case backlash.
HINT:
Push the pinion shaft. Minimum backlash: 0.05 mm (0.0020 in.)
If the backlash is not within the specification, replace the thrust
washer with one of the correct size and reinstall the thrust wash-
er.
Thickness mm (in.)Thickness mm (in.)
1.70 (0.0669)2.45 (0.0965)
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TF0920
Q00534
SST
Q00547
SST
Q00549
TR−22
−
TRANSFER CENTER DIFFERENTIAL
1996 LAND CRUISER (RM451U) 1.85 (0.0728)
2.60 (0.1024)
2.00 (0.0787)2.75 (0.1083)
2.15 (0.0846)2.90 (0.1
142)
2.30 (0.0906)3.05 (0.1201)
(d) In the same way, measure the rear case backlash.
4. INSTALL STRAIGHT PIN TO PINION SHAFT
5. INSTALL REAR SIDE GEAR AND THRUST WASHER
6. INSTALL DIFFERENTIAL REAR CASE
Install the differential rear case and 12 set bolts.
7. TORQUE REAR CASE SET BOLT
(a) Torque the rear case 12 set bolts.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
(b) Turn the pinion gear.
(c) Loosen the rear case 12 set bolts.
(d) Torque the rear case 12 set bolts. Torque: 98 N·m (1,000 kgf·cm, 72 ft·lbf)
8. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing. SST 09316−12010
9. INSTALL CLUTCH HUB
Using SST and a press, install the clutch hub. SST 09316−12010, 09316 −60011 (09316−00011)
10. INSTALL HIGH SPEED OUTPUT GEAR BUSHING
(a) Apply MP grease to the straight pin.
(b) Install the straight pin, as shown.
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Q00546
SST
Q00555
Q00539
SSTSST
Q00540
SST
SST
TF0931
−
TRANSFER CENTER DIFFERENTIAL
TR−23
1996 LAND CRUISER (RM451U)
(c) Using SST and a press, install the high speed output gear
bushing.
SST 09316−12010, 09316 −60011 (09316−00011)
NOTICE:
Before pressing, align the holes on the bushing and shaft
so that the pin on the shaft aligned with the cutting portion
of the bushing.
11. INSTALL HIGH AND LOW CLUTCH SLEEVE
HINT:
Make sure to install the high and low clutch sleeve in the correct
direction.
12. INSTALL HIGH SPEED OUTPUT GEAR AND NEEDLE ROLLER BEARING
(a) Apply gear oil to the needle roller bearing.
(b) Install the high speed output gear and needle roller bear-
ing.
13. INSTALL FRONT TAPER ROLLER BEARING
Using SST and a press, install the front taper roller bearing. SST 09316−12010, 09316 −60011 (09316−00011)
14. INSTALL FRONT DRIVE GEAR PIECE
Using SST and a press, install the front drive gear piece. SST 09316−12010, 09316 −60011 (09316−00011)
15. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.00 (0.0787)G2.60 (0.1024)
B2.10 (0.0827)H2.70 (0.1063)
C2.20 (0.0866)J2.80 (0.1 102)
D2.30 (0.0906)K1.80 (0.0709)
E2.40 (0.0945)L1.90 (0.0748)
F2.50 (0.0984)−−
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TR−24
−
TRANSFER CENTER DIFFERENTIAL
1996 LAND CRUISER (RM451U)
(b) Using a snap ring expander, install a new snap ring.
16. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE (See page TR−19 )
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