1996 TOYOTA LAND CRUISER elec

R08154
Matchmark
(Groove)
5
°
108 ° 1.5 V
32
SA2306
SA1992
R08218
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−47
1996 LAND CRUISER (RM451U)
(b) Ensure that the matchmarks of the pinion of the actuator
is in the extent between zero and 5 degrees clockwise
above the center line of the actuator.
If the matchmarks is not in this extent, rotate the pinion to be
matched. Do not supply the battery positive voltage directly be-
tween terminals. If the matchmarks come to the extension limit
of the rotation, do not electrify moreover.
(c) Install a new O−ring to the actuator.
(d) Apply a light coat of gear oil on the O −ring.
(e) Apply MP grease to the gear part.
(f) Insert the actuator so that the long hole on the actuator side fits with the knock pin on the carrier side.
HINT:
Do not damage the O −ring of the actuator.
(g) Align the actuator with the long hole and rotate the actua-
tor counterclockwise when the knock pin reaches the
right−hand side.
(h) Install the actuator to the differential carrier with the bolt so that the outermost rack tooth of the shift fork will fit the
matchmarks of the pinion of the actuator.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
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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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SA2450
SST
SA2446
R08261
R08262
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−91
1996 LAND CRUISER (RM451U)
(d) 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:
Coat the nut and screw of the drive pinion with gear oil. As
there is no spacer, tighten a little at a time, being careful not
to overtighten.
(e) Using a torque wrench, measure the preload. Preload (at starting):
New bearing
1.3 − 2.0 N·m (13 − 20 kgf·cm, 11.3 − 17.4 in.·lbf)
Reused bearing
0.7 − 1.0 N·m (7 − 10 kgf·cm, 6.1 − 8.7 in.·lbf)
HINT:
Measure the total preload after first turning the bearing clock-
wise and counterclockwise several times to make the bearing
smooth.
10. w/o DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the 2 bearing outer races on their respective bear- ings. Make sure that the left and right outer races are not
interchanged.
(b) Install the case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
11. w/ DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the 2 bearing outer races on their respective bear- ings. Make sure that the left and right races are not inter-
changed.
(b) Install the assembled plate washer onto the side bearing.
(c) Install the differential case in the carrier.
(d) Make the plate washer and bearing smooth by tapping on
the ring gear with a plastic hammer.
HINT:
If it is difficult to install the differential case into the carrier, re-
place the plate washer with a thinner one.
However, select a plate washer that allows no clearance be-
tween it and the carrier.
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R08263
R08264
R08265
SA−92
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
12. w/ DIFFERENTIAL LOCK:
ADJUST RING GEAR BACKLASH
(a) Using a dial indicator, with holding the side bearing of the
ring gear side and measure the backlash.
Backlash (reference): 0.15 mm (0.0059 in.)
(b) Select a case cover side plate washer using the backlash
as reference.

Side plate washer thickness
(c) Select a ring gear side plate washer of a thickness which
eliminates any clearance between the plate washer and
carrier.
(d) Remove the 2 plate washers and differential carrier.
(e) Install the plate washer into the lower part of the carrier.
(f) Place the plate washer onto the dif ferential case together
with the outer race, and install the differential case with
the outer race into the carrier.
(g) Using a plastic hammer, make the washer and bearing smooth by tapping the ring gear.
(h) Using a dial indicator, measure the ring gear backlash. Backlash: 0.15 − 0.20 mm (0.0059 − 0.0079 in.)
If it is not within the specification, adjust it by either increasing
or decreasing the number of washers on both sides by an equal
amount.
HINT:
There should be no clearance between the plate washer and
case.
Ensure that there is ring gear backlash.
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RA0090
R08269
SST
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−93
1996 LAND CRUISER (RM451U)
13. w/ DIFFERENTIAL LOCK:
ADJUST SIDE BEARING PRELOAD
(a) After adjustment with the backlash as reference, remove
the ring gear side plate washer.
(b) Using a micrometer, measure the thickness of the re- moved plate washer.
(c) Install a new thicker washer of 0.06 − 0.09 mm (0.0024 −
0.0035 in.) than the washer removed.
HINT:
Select a washer which can be pressed in 2/3 of the way with fin-
ger.
(d) Using SST, tap in the plate washer. SST 09504−22010
(e) Align the matchmarks on the cap and carrier.
(f) Tighten the 4 bearing cap bolts to the specified torque. Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
(g) Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.15 − 0.20 mm (0.0059 − 0.0079 in.)
If it is not within the specification, follow the procedure listed be-
low.
If backlash is greater than the specification:
Replace the cover side washer with a thicker washer. When do-
ing so replace the ring gear side plate washer with one having
a thickness equalling the amount the cover side plate washer
thickness was decreased.
If backlash is less than specification:
Replace the cover side washer with a thicker washer. When do-
ing so, replace the ring gear side plate washer with one having
a thickness equalling the amount the cover side plate washer
thickness was increased.
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FA2013
Proper ContactHeel Contact
Face Contact
Select an adjusting washer that will bring the drive
pinion closer to the ring gear.
Select an adjusting washer that will shift the drive
pinion away from the ring gear.
Toe Contact
Flank Contact
FA2041
Washer
SA2394
SA−96
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.
Thickness mm (in.)Thickness mm (in.)
1.05 (0.0413)1.35 (0.0531)
1.10 (0.0433)1.40 (0.0551)
1.15 (0.0453)1.45 (0.0571)
1.20 (0.0472)1.50 (0.0591)
1.25 (0.0492)1.55 (0.0610)
1.30 (0.0512)−
19. REMOVE COMPANION FLANGE (See page SA−29)
20. REMOVE OIL SLINGER AND FRONT BEARING (See
page SA−29 )
21. INSTALL BEARING SPACER AND FRONT BEARING
(a) Install a new bearing spacer on the shaft.
(b) Install the front bearing and oil slinger.
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SA1VO−02
Z07259
Outside
Actuator Installation
Hole Shift Fork
R08154
3
2
1.5
50 °
108 °
Matchmark
(Groove)
SA2306
SA2420
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
SA−109
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL FRONT ACTUATOR
(a) Check that the outermost rack tooth of the shift fork is
virtually above the center line of the actuator installation
hole.
(b) Using a dry cell battery, alig n the matchmark on the pinion
with the center line of the actuator.
NOTICE:
If the pinion of the actuator is not in the specified
place, the actuator is difficult to be installed.
Do not supply the battery positive voltage between
terminals.
If the matchmark comes to the extension limit of the
rotation, do not electrify moreover.
(c) Install a new O−ring to the actuator.
(d) Apply a light coat of gear oil on the O −ring.
(e) Apply MP grease to the gear part of the actuator.
(f) Install the actuator to the differential with the 2 nuts and bolt, so that the outermost rack tooth of the shift fork will
fit matchmark of the pinion of the actuator.
HINT:
Do not damage the O −ring of the actuator.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
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SF1ED−04
−
SFI SFI SYSTEM
SF−1
629
Author: Date:
1996 LAND CRUISER (RM451U)
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCON-
NECT NEGATIVE (−) TERMINAL CABLE FROM THE
BATTERY.
HINT:
Any diagnostic trouble code retained by the computer will be
erased when the negative ( −) terminal cable is disconnected.
Therefore, if necessary, read the diagnosis before disconnect-
ing the negative ( −) terminal cable from the battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM.
3. KEEP GASOLINE AWAY FROM RUBBER OR
LEA TH-
ER PARTS
4. MAINTENANCE PRECAUTIONS
(a) In event of engine misfire, these precautions should be taken.
(1) Check proper connection of battery terminals, etc.
(2) Handle high −tension cords carefully.
(3) After repair work, check that the ignition coil termi- nals and all other ignition system lines are recon-
nected securely.
(4) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(b) Precautions when handling the oxygen sensor. (1) Do not allow the oxygen sensor to drop or hit
against an object.
(2) Do not allow the sensor to come in contact with wa- ter.
5. IF VEHICLE IS EQUIPPED WITH MOBILE RA-
DIO
SYSTEM (HAM, CB, ETC.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
6. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will allow air suction and cause the engine to run out
of tune.
7. ELECTRONIC CONTROL SYSTEM
(a) Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition
switch OFF or disconnecting the negative ( −) terminal
cable from the battery.
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