1996 TOYOTA LAND CRUISER Front diff

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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SA−34
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
4 Pinion gears
4 Pinion gear thrust washers
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SA1UO−01
SA2419
SST
SA2418
SST
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−35
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REMOVE DUST DEFLECTOR TO COMPANION
FLANGE
Using SST and a press, remove the dust deflector. SST 09950−00020
2. INSTALL DUST DEFLECTOR TO COMPANION FLANGE
Using SST and a press, install a new dust deflector. SST 09726−40010
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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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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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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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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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