Page 1095 of 1399
FA2045
SST
SA2431
SST
Rear Bearing Outer Race
SA2410
Oil Strage Ring
Front Bearing
Outer Race
SA−32
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
HINT:
Tag the disassembled parts to show the location for reassemb-
ly.
(f) w/ Differential lock:
Remove the differential case with the side bearing outer
race, adjusting nuts and sleeve from the differential carri-
er.
(g) w/ Differential lock: Remove the shift fork.
15. REMOVE DRIVE PINION AND BEARING SPACER
(a) Remove the drive pinion with the front bearing.
(b) Remove the bearing spacer.
16. REMOVE DRIVE PINION FRONT BEARING
(a) Using SST and a press, remove the 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.
17. REMOVE FRONT AND REAR BEARING OUTER
RACES AND OIL STORAGE RING
(a) Using SST, remove the rear bearing outer race. SST 09308−00010
(b) Using a brass bar and hammer, remove the oil storage ring and front bearing outer race.
HINT:
Do not remove the oil storage ring unless replacing it with a new
one.
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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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SA1987
SA1978
SA1976
FA2037
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−37
1996 LAND CRUISER (RM451U)
3. w/ DIFFERENTIAL LOCK:
MEASURE CLEARANCE OF SHIFT FORK AND
SLEEVE
Using a feeler gauge, measure the clearance between the shift
fork and sleeve. Clearance:
0.15 − 0.35 mm (0.006 − 0.014 in.)
4. w/ DIFFERENTIAL LOCK: ASSEMBLE DIFFERENTIAL CASE
(a) Apply all of the sliding and rotating sufaces with gear oil.
(b) Install the side gear thrust washer to the side gear.
(c) Install the side gear to the RH case.
(d) Install the 4 pinion gears and pinion gear thrust washers to the spider.
(e) Install the pinion gear with the spider to the RH case.
(f) Using a dial indicator, holding the side gear and spider and measure the side gear backlash.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
HINT:
Measure at all 4 locations.
Measure the backlash at the RH case and at the LH case.
If the backlash is not within the specification, install a thrust
washer of a different thickness. Thrust washer thickness
Thickness mm (in.)Thickness mm (in.)
0.9 (0.035)1.2 (0.047)
1.0 (0.039)1.3 (0.051)
1.1 (0.043)−
(g) Install the side gear and side gear thrust washer to the RH
case.
(h) Install the pinion gears and spider to the RH case.
(i) Install the side gear and side gear thrust washer to the RH
case.
(j) Align the matchmarks on the LH and RH cases.
(k) Torque the 8 bolts uniformly, a little at a time. Torque: 47 N·m (480 kgf·cm, 35 ft·lbf)
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Page 1101 of 1399
SA2160
Boiling Water
SA2178
SA2182
SA−38
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
5. INSTALL SIDE BEARINGS
w/o Differential lock:
Using SST and a press, install the 2 side bearings on the
differential case.
SST 09950−60010 (09951 −00480)
w/ Differential lock:
Using SST and a press, install the 2 side bearings on the
differential case.
SST 09223−15020, 09950 −60010 (09951−00480)
6. 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 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 new 5 lock plates and 10 set bolts.
NOTICE:
The ring gear set bolts should not tighten until the ring gear
has cooled sufficiently.
(g) After the ring gear cools down enough, tighten the set bolts uniformly and a little at a time.
Torque: 97 N·m (985 kgf·cm, 71 ft·lbf)
(h) Using a drift punch and hammer, stake the lock plates.
HINT:
Stake one claw flush with the flat surface of the bolt. For the
claw contacting the protruding portion of the bolt, stake only the
half on the tightening side.
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Page 1102 of 1399
SA2465
SA2406
SST
SA2203
SSTSST
Front
Rear
FA2042
SST
R13140
SST
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−39
1996 LAND CRUISER (RM451U)
7. CHECK RING GEAR RUNOUT
(a) Install the differential case onto the carrier and tighten the
adjusting nut just to where there is no play in the bearings.
(b) Using a dial indicator, check the ring gear runout. Maximum runout: 0.10 mm (0.0039 in.)
(c) Remove the differential case.
8. INSTALL OIL STORAGE RING
Using SST and a hammer, install a new oil storage ring. SST 09316−60011 (09316 −00011, 09316−00021)
9. INSTALL DRIVE PINION FRONT AND REAR BEARING
OUTER RACES
Front side:
Using SST and a press, install the 2 outer races.
SST 09316−60011 (09316 −00011, 09316−00051)
Rear side:
Using SST and a press, install the 2 outer races.
SST 09316−60011 (09316 −00011, 09316−00021)
10. INSTALL DRIVE PINION FRONT BEARING
(a) Install the plate washer on the drive pinion with the cham-
fered end facing the pinion gear.
(b) Using SST and a press, install the front bearing onto the
drive pinion.
SST 09506−30012
11. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion, rear bearing and oil slinger.
HINT:
Assemble the spacer and oil seal after adjusting the gear con-
tact pattern.
(b) Install the companion flange with SST. SST 09550 −30010 (09951 −03010, 09953 −03010,
09954 −03010, 09955 −03030, 09956−03020)
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Page 1106 of 1399
FA2041
Washer
W00529
SA2407
SST
R13140
SST
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−43
1996 LAND CRUISER (RM451U)
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.
Washer thickness
Thickness mm (in.)Thickness mm (in.)
1.70 (0.0669)2.03 (0.0799)
1.73 (0.0681)2.06 (0.0811)
1.76 (0.0693)2.09 (0.0823)
1.79 (0.0705)2.12 (0.0835)
1.82 (0.0717)2.15 (0.0846)
1.85 (0.0728)2.18 (0.0858)
1.88 (0.0740)2.21 (0.0870)
1.91 (0.0752)2.24 (0.0882)
1.94 (0.0764)2.27 (0.0894)
1.97 (0.0776)2.30 (0.0906)
2.00 (0.0787)2.33 (0.0917)
18. REMOVE COMPANION FLANGE (See page SA−29)
19. REMOVE OIL SLINGER AND REAR BEARING
20. REMOVE REAR BEARING OUTER RACE AND OIL STORAGE RING (See page SA−29 )
21. INSTALL BEARING SPACER AND REAR BEARING
(a) Install a new bearing spacer on the shaft.
(b) Install a new oil storage ring and rear bearing outer race (See page SA−29 ).
(c) Install the rear bearing and oil slinger.
22. INSTALL OIL SEAL
(a) Using SST, install a new oil seal, as shown. SST 09214−76011
Oil seal drive in depth: 1.0 mm (0.039 in.)
(b) Apply MP grease to the oil seal lip.
23. INSTALL COMPANION FLANGE
(a) Install the companion flange with SST. SST 09550 −30010 (09951 −03010, 09953 −03010,
09954 −03010, 09955 −03030, 09956−03020)
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Page 1107 of 1399
SA2390
SST
SA2403
SA2471
SA−44
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
(b) Install the plate washer and a new nut.
HINT:
Coat the threads of a new nut with gear oil.
(c) Using SST to hold the flange, tighten the nut.
SST 09330−00021
Torque: 196 N·m (2,000 kgf·cm, 145 ft·lbf)
24. ADJUST DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash
between the drive pinion and ring gear. 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)
If the preload is greater than the specification, replace the bear-
ing spacer.
If the preload is less than the specification, retighten the nut a
little at a time with a torque of 13 N·m (130 kgf·cm, 9 ft·lbf) until
the specified preload is reached. Maximum torque: 343 N·m (3,500 kgf·cm, 253 ft·lbf)
If the maximum torque is exceeded while retightening the nut,
replace the bearing spacer and repeat the preload procedure.
Do not back off the pinion nut to reduce the preload.
25. RECHECK RING GEAR BACKLASH
26. RECHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
27. CHECK RUNOUT OF COMPANION FLANGE
28. STAKE DRIVE PINION NUT
29. INSTALL ADJUSTING NUT LOCKS
(a) Install 2 new nut locks on the bearing caps. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) After tightening bolts, bend the nut locks.
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Page 1108 of 1399
SA2417
Holes
Groore
Z15179
FIPG Width Approx.
1 − 2 mm (0.04 − 0.08 in.)
Z10101
Adhesive
SA2205
SA1979Lock
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−45
1996 LAND CRUISER (RM451U)
30. w/ DIFFERENTIAL LOCK:
INSTALL SHIFT FORK SHAFT
(a) Apply MP grease onto the outer circuit of the fork shaft.
(b) Install the fork shaft to match the hole of the shift fork and
that of the shift fork shaft.
(c) Remove any FIPG material and be careful not to drop oil on the contacting surface of the differential carrier and
shaft retainer.
(d) Apply FIPG to the carrier, as shown. FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
HINT:
Install the shaft retainer within 10 minutes after applying FIPG.
(e) Clean the threads of the bolts and retainer bolts holes with
toluene or trichlorethylene.
(f) Apply adhesive to 2 or 3 threads of the mount bolt end. Adhesive: Part No. 08833 −00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(g) Tighten the shaft retainer with the 2 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(h) Using a pin punch and hummer, install the slotted spring pin to the shift fork.
(i) Shift the fork deeply and keep the differential lock condi- tion.
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