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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SA2401
SST
SA2403
SA2161
MP Grease
Z10100
SA−40
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
(c) 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:
As there is no spacer, tighten a little at a time, being careful
not to overtighten.
(d) Using a torque wrench, measure the preload. 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)
HINT:
Measure the total preload after first turning the bearing clock-
wise and counterclockwise several times to mark the bearing
smooth.
12. w/o DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the bearing outer races on their respective bear- ings. Make sure the left and right outer races are not inter-
changed.
(b) Install the case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
13. w/ DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Apply MP grease on the rack of the shift fork and connect- ing part of the indicator switch.
(b) Insert the shift fork into the differential carrier, as shown.
(c) Install outer races, adjusting nuts and left side to sleeve.
HINT:
Check that the sleeve moves smoothly.
(d) Install the shift fork in the groove of the sleeve holding it by hand and install the case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
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Z06898
SA2458
Matchmarks
SA2467SST
Z10281SST
SA2308
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−41
1996 LAND CRUISER (RM451U)
14. w/o DIFFERENTIAL LOCK:
INSTALL ADJUSTING NUTS
Install the adjusting nuts on the carrier , making sure the nuts are
threaded properly.
15. INSTALL BEARING CAPS
Align the matchmarks on the cap and carrier. Screw in the 2
bearing cap bolts 2 or 3 turns and press down the bearing cap
by hand.
HINT:
If the bearing cap does not fit tightly on the carrier , the adjusting
nuts are not threaded properly.
Reinstall the adjusting nuts if necessary.
16. ADJUST SIDE BEARING PRELOAD
(a) Torque the 4 bearing cap bolts to the specified torque, and loosen them to the point where the adjusting nuts can
be turned by SST.
SST 09504−00011
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(b) Fully tighten the 4 bearing cap bolts by hand.
(c) Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008
in.).
(d) With turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side. After the bearings
are settled, loosen the adjusting nut on the drive pinion
side.
(e) Place a dial indicator on the top of the adjusting nut on the ring gear side.
(f) Adjust the side bearing for zero preload by tightening the
other adjusting nut until the pointer on the indicator be-
gins to move.
(g) Torque the adjusting nut 1 − 1.5 notches from the zero preload position.
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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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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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R13413
R08152
SA1993
R08153
Outside
Shift Fork
Actuator Installation
Hole
SA−46
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
(j) Install the ball, compression spring and spring seat.
(k) Clean the threads of 2 plugs and plug holes with toluene
or trichloroethylene.
(l) Apply adhesive to the plug threads. Adhesive: Part No. 08833 −00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(m) Using a hexagon wrench, install and tighten the screw
plugs.
Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)
31. w/ DIFFERENTIAL LOCK: MEASURE DISTANCE BETWEEN SLEEVE AND DIF-
FERENTIAL CASE END SIDE
Measure distance between the sleeve and tip of the differential
case when differential is free and locked. Standard distance:
LOCK: 17.44 − 18.86 mm (0.6866 − 0.7425 in.)
FREE: 32.40 − 33.90 mm (1.2756 − 1.3346 in.)
32. w/ DIFFERENTIAL LOCK: INSTALL INDICATOR SWITCH
Install the indicator switch with a new gasket. Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
33. w/ DIFFERENTIAL LOCK: INSTALL ACTUATOR
(a) Check that the outermost rack tooth of the shift fork is virtually above the center line of the actuator installation
hole.
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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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SA1UQ−01
SA−48
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (see page SA−27).
HINT:
w/ differential lock:
Before installation, check differential lock operation connecting the connector of the actuator to the
connector of the vehicle side.
w/ differential lock:
Before installation, check that the sleeves on work with switching over the differential lock control
switch.
After checking, lock the front differential.
After installation, fill the differential with gear oil (See page SA−27).
w/ differential lock:
After installation, check that the bleeder plug at the point of the bleeder tu\
be (inside of the engine room)
is not damaged or worn.
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