1996 TOYOTA LAND CRUISER torque

SS1EK−02
−
SERVICE SPECIFICATIONS BODY
SS−41
164
Author: Date:
1996 LAND CRUISER (RM451U)
BODY
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
FRONT BUMPER
Front bumper arm x Front bumper bracket3940029
Front bumper arm x Body3940029
Front bumper extension x Front bumper5.45548 in.·lbf
REAR BUMPER
Rear bumper extension x Rear bumper reinforcement131309
Rear bumper extension reinforcement x Body5.45548 in.·lbf
HOOD
Hood hinge x Body1818513
Hood lock x Body88069 in.·lbf
FRONT DOOR
Door hinge x Body2424017
Door hinge x Door panel2424017
Door lock x Door panel55043 in.·lbf
Window regulator x Door panel55043 in.·lbf
REAR DOOR
Door hinge x Body2424017
Door hinge x Door panel2424017
Door lock x Door panel55043 in.·lbf
Window regulator x Door panel55043 in.·lbf
WIPER AND WASHER
Front wiper arm x Wiper link2021015
Wiper link x Body5.45548 in.·lbf
Wiper motor x Body5.45548 in.·lbf
Rear wiper arm x Wiper motor5.45548 in.·lbf
WHEEL OPENING EXTENSION
Front wheel opening extension x Body5.45548 in.·lbf
Rear wheel opening extension x Body5.45548 in.·lbf
INSTRUMENT P ANEL
Front passenger airbag assembly x Instrument panel reinforcement2021015
FRONT MANUAL SEAT
Seat truck x Body3940029
Seat reclining assembly x Seatback frame5253038
Lumber support x Seatback frame1818513
FRONT POWER SEAT
Seat truck x Body3940029
Power seat adjuster x Seatback frame3737527
Power seat adjuster x Seatback cushion frame1818513
Lumber support x Seatback frame1818513
NO. 1 REAR SEAT
Seat cushion hinge x Body3940029
Seat cushion hinge x Seat cushion frame3940029
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SS1EM−02
SS−44
−
SERVICE SPECIFICATIONS AIR CONDITIONING
1996 LAND CRUISER (RM451U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Compressor x Suction hose101007
Compressor x Discharge hose101007
Condensser x Compressor bracket2525018
Compressor bracket x Engine3737527
Receiver x Liquid tube5.45548 in.·lbf
Condenser x Discharge hose101007
Cooling unit x Liqied tube101007
Cooling unit x Suction tube101007
Pressure switch x Liquid tube101007
Expansion valve x Evaporetor5.45548 in.·lbf
Liquid line (Union nut)1414010
Suction line (bolt)101407
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ST0KP−01
ST−4
−
STARTING STARTER
1996 LAND CRUISER (RM451U)
REMOVAL
REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire. Torque: 8.8 N·m (90 kgf·cm, 70 in.·lbf)
(c) Remove the 2 bolts and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
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ST0KQ−01
P23005
P23006
P08385
P23007
−
STARTING STARTER
ST−5
1996 LAND CRUISER (RM451U)
DISASSEMBLY
HINT:
At the time of reassembly, use high−temperature grease to lu-
bricate the bearings, gears, return spring and steel ball when
assembling the starter.
1. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(b) Remove the 2 through bolts. Torque:
1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
2.0 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
(c) Pull out the field frame with the armature from the magnet-
ic switch assembly.
(d) Remove the O−ring.
HINT:
At the time of reassembly, use a new O−ring.
HINT:
At the time of reassembly, align the protrusion of the field frame
with cutout of the magnetic switch.
2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR
(a) Remove the 2 screws.
Torque:
1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
2.0 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
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P04683(1) (5)(4)
(2)
(3)
P04515
Magnetic Finger
P23004
P04525
ST−6
−
STARTING STARTER
1996 LAND CRUISER (RM451U)
(b) Remove these parts from the magnetic switch assembly:
(1) Starter housing
(2) Return spring
(3) Bearing
(4) Idler gear
(5) Starter clutch assembly
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
4. REMOVE BRUSH HOLDER
(a) Remove the 2 screws, 2 O −rings and end cover from the
field frame.
Torque:
1.4 kW type: 1.5 N·m (15 kgf·cm, 13 in.·lbf)
2.0 kW type: 3.8 N·m (40 kgf·cm, 35 in.·lbf)
HINT:
At the time of reassembly, use new O−rings.
(b) Remove the O−ring from the field frame.
HINT:
At the time of reassembly, use a new O−ring.
(c) Using a screwdriver, hold the spring back and disconnect
the brush from the brush holder. Disconnect the four
brushes and remove the brush holder.
5. REMOVE ARMATURE FROM FIELD FRAME
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ST−14
−
STARTING STARTER
1996 LAND CRUISER (RM451U)
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (173 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
8. CLEAN CONTACT SURFACES OF CONTACT PLATE AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
9. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp with
the 3 bolts. Torque:
1.4 kW type: 2.5 N·m (25 kgf·cm, 22 in.·lbf)
2.0 kW type: 3.6 N·m (37 kgf·cm, 32 in.·lbf)
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TR0CM−01
Q07105
Q07124
FIPG
TR−4
−
TRANSFER TRANSFER ASSEMBLY
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE BREATHER HOSE
2. REMOVE DYNAMIC DAMPER
Remove the 2 bolts and dynamic damper.
HINT:
At the time of reassembly, apply adhesive to the bolt threads. Adhesive: Part No.08833 −00070, THREE BOND 1324
or equivalent
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
3. REMOVE MOTOR ACTUATOR
Remove the 4 bolts and motor actuator.
HINT:
At the time of reassembly, please refer to the following items.
Set the motor actuator in differential lock condition.
Apply FIPG to the front case.
FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
4. REMOVE OUTPUT GEAR FROM FRONT CASE
HINT:
At the timie of reassembly apply gear oil to the output gear.
NOTICE:
At the time of reassembly, do not turn the output gear.
5. REMOVE SCREW PLUG, SPRING AND BALL
(a) Using a torx socket wrench (T40), remove the screw plug.
HINT:
At the time of reassembly, apply liquid sealer to the screw plug. Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
Torque:19 N·m (190 kgf·cm, 14 ft·lbf)
(b) Using a magnetic finger, remove the spring and ball.
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Q04610
Q00541
Front
Q02950
Q07125
FIPG
−
TRANSFER TRANSFER ASSEMBLY
TR−5
1996 LAND CRUISER (RM451U)
6. REMOVE TRANSFER INDICATOR SWITCH
Remove the Center Diff Lock indicator switch, L4 position
switch, Neutral position switch and 3 gaskets.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
7. REMOVE FRONT EXTENSION HOUSING
Remove the 6 bolts and front extension housing.
HINT:
If necessary, tap the front extension housing with a plastic ham-
mer.
HINT:
At the time of reassembly, please refer to the following items.
Set the clutch sleeve in differential lock condition.
Apply FIPG to the front case.
FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
8. REMOVE CLUTCH SLEEVE, SHIFT FORK NO.2 SHAFT AND SHIFT FORK NO.2
HINT:
At the time of reassebly, make sure to install the clutch sleeve
in the correct direction.
9. SEPARATE SHIFT FORK NO.2 SHAFT AND SHIFT FORK NO.2
(a) Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the shift fork No.2 shaft.
(b) Separate the shift fork No.2 shaft and shift fork No.2.
10. REMOVE REAR EXTENSION HOUSING
Remove the 9 bolts and rear extension housing.
HINT:
If necessary, tap the rear extension housing with a plastic ham-
mer.
HINT:
At the time of reassembly, apply FIPG to the rear case. FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
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Version 1.11 - 03/16/2010