1996 TOYOTA LAND CRUISER lock

SA1UM−03
FA2038
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−27
1996 LAND CRUISER (RM451U)
REMOVAL
1. w/ DIFFERENTIAL LOCK:
BEFORE REMOVAL, SHIFT FRONT DIFFERENTIAL
TO LOCK
(a) Turn the ignition switch to the ON position.
(b) Keep the center differential lock condition.
(c) Turn the differential lock control switch to the FR/RR posi-
tion and lock the front differential.
(d) Rotating the tires, check they are in the differential lock condition.
(e) Disconnect the cable from the negative terminal of the battery.
2. DRAIN DIFFERENTIAL OIL
3. REMOVE FRONT AXLE SHAFTS (See page SA−13)
4. REMOVE TIE ROD FROM KNUCKLE ARM (See page SA−13 )
5. REMOVE FRONT PROPELLER SHAFT (See page PR−3 )
6. w/ DIFFERENTIAL LOCK: DISCONNECT CONNECTORS AND TUBE
HINT:
When connecting the tube of the harness side to the hose
of the actuator side, its depth of insertion is 15 mm (0.59
in.).
Take care that water or equivalent does not adhere to the
connector and hose.
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Z10092
w/o Differential Lock
w/ Differential Lock
SA−28
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
7. REMOVE DIFFERENTIAL CARRIER ASSEMBLY
(a) Remove the 10 nuts, washers and differential carrier as-
sembly.
NOTICE:
Be careful not to damage the installation surface. Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)
(b) Remove the gasket.
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SA2442
R13332
SA2206
Z10098
SA−30
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
6. w/o DIFFERENTIAL LOCK:
CHECK SIDE GEAR BACKLASH
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 the correct
thrust washers (See page .SA−35 ).
7. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See page SA−35 )
8. w/ DIFFERENTIAL LOCK: REMOVE ACTUATOR
(a) Remove the bolt and actuator from the differential carrier.
(b) Remove the O−ring.
9. w/ DIFFERENTIAL LOCK: REMOVE INDICATOR SWITCH
Remove the indicator switch and gasket.
10. w/ DIFFERENTIAL LOCK:
REMOVE SHIFT FORK SHAFT
(a) Using a hexagon wrench, remove the 2 straight screw plugs.
(b) Remove the spring seat, compression spring and ball.
(c) Using a pin punch and hammer , remove the slotted spring
pin.
(d) Remove the 2 bolts from the shaft retainer.
(e) Using a plastic hammer, tap out the shaft retainer.
(f) Remove the shift fork shaft.
HINT:
Pull out the shift fork shaft with a screwdriver turned round.
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SA2405
SST
R13141
SST
SA2402
SST
Z00641
SST
R13142
Matchmarks
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−31
1996 LAND CRUISER (RM451U)
11. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake the nut.
(b) Using SST to hold the flange, remove the nut and plate
washer.
SST 09330−00021
(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 REAR BEARING
Using SST, remove the rear bearing from the drive pinion. SST 09556−22010
14. REMOVE DIFFERENTIAL CASE
(a) Place matchmarks on the bearing cap and dif ferential car-
rier.
(b) Remove the 2 adjusting nut locks.
(c) Remove the 4 bolts and 2 bearing caps.
(d) w/o Differential lock: Remove the 2 adjusting nuts.
(e) w/o Differential lock: Remove the differential case with the side bearing outer
races from the carrier.
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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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Z15178
Matchmarks
SA2464
W03472
SST
RA0997
FA2046
Matchmarks
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−33
1996 LAND CRUISER (RM451U)
18. REMOVE RING GEAR
(a) Using a screwdriver and hammer, unstake the lock plate.
(b) Place matchmarks on the ring gear and differential case.
(c) Remove the ring gear 10 set bolts and 5 lock plates.
(d) Using a plastic hammer, tap on the ring gear to separate
it from the differential case.
19. 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.
20. REMOVE SIDE BEARING FROM DIFFERENTIAL CASE
Using SST, pull the side bearing from the differential case. SST 09950 −40010 (09951 −04010, 09952 −04020,
09953 −04020, 09954 −04010, 09955 −04010,
09957 −04010, 09958 −04010),
09950 −60010 (09951 −00480)
HINT:
Fix the claws of SST to the notches in the differential case.
21. w/o DIFFERENTIAL LOCK: DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, remove the straight pin.
(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
22. w/ DIFFERENTIAL LOCK: DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the LH and RH cases.
(b) Remove the 8 bolts uniformly, a little at a time.
(c) Using a plastic hammer, separate the LH and RH cases.
(d) Remove these parts from the RH differential case:
2 Side gears
2 Side gear thrust washers
Spider
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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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