1996 TOYOTA LAND CRUISER clutch

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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TR0B8−01
Z15264
Front Taper Roller BearingIdler Gear
High and Low
Clutch SleeveNeedle Roller Bearing
Idler
Low Gear Rear Taper
Roller Bearing
−
TRANSFER IDLER GEAR
TR−15
825
Author: Date:
1996 LAND CRUISER (RM451U)
IDLER GEAR
COMPONENTS
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Version 1.11 - 03/16/2010

TR0B9−01
TF0887
TF0888
Q07132
SST
Q07100
Socket Wrench
TR−16
−
TRANSFER IDLER GEAR
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. INSPECT IDLER LOW GEAR RADIAL AND THRUST
CLEARANCE
(a) Using a feeler gauge, measure the idler low gear thrust clearance.
Standard clearance:
0.125−0.275 mm (0.0049 −0.0108 in.)
Maximum clearance:
0.275 mm (0.0108 in.)
(b) Using a dial indicator, measure the idler low gear radial clearance.
Standard clearance:
0.015−0.068 mm (0.0006 −0.0027 in.)
Maximum clearance:
0.068 mm (0.0027 in.)
2. REMOVE FRONT TAPER ROLLER BEARING
Using SST, remove the front taper roller bearing. SST 09950−40010
3. REMOVE REAR TAPER ROLLER BEARING
Using SST, a press and socket wrench, remove the rear taper
roller bearing. SST 09950−00020
4. REMOVE IDLER LOW GEAR AND NEEDLE ROLLER BEARING FROM IDLER GEAR
5. REMOVE HIGH AND LOW CLUTCH SLEEVE FROM IDLER GEAR
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TR0BA−01
TF0893
SST
Q00538
TF0896
SST
−
TRANSFER IDLER GEAR
TR−17
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL FRONT TAPER ROLLER BEARING
Using SST and a press, install the front taper roller bearing.
SST 09316−60011 (09316 −00011, 09316−00031)
2. INSTALL HIGH AND LOW CLUTCH SLEEVE
HINT:
Make sure to install the high and low clutch sleeve in the correct
direction.
3. INSTALL NEEDLE ROLLER BEARING AND IDLER LOW GEAR TO IDLER GEAR
(a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing and idler low gear.
4. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing. SST 09316−60011 (09316 −00011, 09316−00071)
5. INSPECT IDLER LOW GEAR RADIAL AND THRUST CLEARANCE
(See page TR−16 )
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TR0BB−01
Q07134
Front Drive Gear
PieceHigh
Speed Output GearHigh Speed Output
Gear Bushing
Clutch HubHigh and Low
Clutch Sleeve Rear Taper Roller
Bearing
 Snap Ring
Needle Roller Bearing
Thrust Washer
Thrust Washer Rear Side Gear
Straight Pin x 12
Differential Rear Case
Thrust Washer
Pinion
Gear
Pinion Shaft
Front Side Gear
Thrust Washer
Differential Front Case
 Non− reusable part Low Gear
Straight Pin

Snap Ring Front T
aper Roller BearingNeedle Roller Bearing
Pinion Gear
TR−18
−
TRANSFER CENTER DIFFERENTIAL
828
Author: Date:
1996 LAND CRUISER (RM451U)
CENTER DIFFERENTIAL
COMPONENTS
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Version 1.11 - 03/16/2010

TR0BC−01
TF0900
TF0944
Q07101
SST
Q07102
SST
Q07103
SST
−
TRANSFER CENTER DIFFERENTIAL
TR−19
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND
THRUST CLEARANCE
(a) Using a feeler gauge, measure the high speed output gear thrust clearance.
Standard clearance:
0.10−0.25 mm (0.0039 −0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)
(b) Using a dial indicator, measure the high speed output gear radial clearance.
Standard clearance:
0.035−0.091 mm (0.0014 −0.0036 in.)
Maximum clearance:
0.091 mm (0.0036 in.)
2. REMOVE FRONT DRIVE GEAR PIECE
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the front drive gear piece.
SST 09950−00020, 09950 −60010 (09951−00320)
NOTICE:
Be careful not to drop the center differential assembly.
3. REMOVE FRONT TAPER ROLLER BEARING
Using SST and a press, remove the front taper roller bearing.
SST 09950−00020
4. REMOVE HIGH SPEED OUTPUT GEAR
5. REMOVE NEEDLE ROLLER BEARING
6. REMOVE HIGH AND LOW CLUTCH SLEEVE AS-
SEMBLY
7. REMOVE HIGH SPEED OUTPUT GEAR BUSHING AND CLUTCH HUB
(a) Using SST and a press, remove the high speed output
gear bushing and clutch hub.
SST 09550−00020, 09950 −00030, 09950−60010
(09951 −00320)
(b) Using a magnetic finger, remove the straight pin from the
differential front case.
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TF0920
Q00534
SST
Q00547
SST
Q00549
TR−22
−
TRANSFER CENTER DIFFERENTIAL
1996 LAND CRUISER (RM451U) 1.85 (0.0728)
2.60 (0.1024)
2.00 (0.0787)2.75 (0.1083)
2.15 (0.0846)2.90 (0.1
142)
2.30 (0.0906)3.05 (0.1201)
(d) In the same way, measure the rear case backlash.
4. INSTALL STRAIGHT PIN TO PINION SHAFT
5. INSTALL REAR SIDE GEAR AND THRUST WASHER
6. INSTALL DIFFERENTIAL REAR CASE
Install the differential rear case and 12 set bolts.
7. TORQUE REAR CASE SET BOLT
(a) Torque the rear case 12 set bolts.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
(b) Turn the pinion gear.
(c) Loosen the rear case 12 set bolts.
(d) Torque the rear case 12 set bolts. Torque: 98 N·m (1,000 kgf·cm, 72 ft·lbf)
8. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing. SST 09316−12010
9. INSTALL CLUTCH HUB
Using SST and a press, install the clutch hub. SST 09316−12010, 09316 −60011 (09316−00011)
10. INSTALL HIGH SPEED OUTPUT GEAR BUSHING
(a) Apply MP grease to the straight pin.
(b) Install the straight pin, as shown.
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Q00546
SST
Q00555
Q00539
SSTSST
Q00540
SST
SST
TF0931
−
TRANSFER CENTER DIFFERENTIAL
TR−23
1996 LAND CRUISER (RM451U)
(c) Using SST and a press, install the high speed output gear
bushing.
SST 09316−12010, 09316 −60011 (09316−00011)
NOTICE:
Before pressing, align the holes on the bushing and shaft
so that the pin on the shaft aligned with the cutting portion
of the bushing.
11. INSTALL HIGH AND LOW CLUTCH SLEEVE
HINT:
Make sure to install the high and low clutch sleeve in the correct
direction.
12. INSTALL HIGH SPEED OUTPUT GEAR AND NEEDLE ROLLER BEARING
(a) Apply gear oil to the needle roller bearing.
(b) Install the high speed output gear and needle roller bear-
ing.
13. INSTALL FRONT TAPER ROLLER BEARING
Using SST and a press, install the front taper roller bearing. SST 09316−12010, 09316 −60011 (09316−00011)
14. INSTALL FRONT DRIVE GEAR PIECE
Using SST and a press, install the front drive gear piece. SST 09316−12010, 09316 −60011 (09316−00011)
15. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.00 (0.0787)G2.60 (0.1024)
B2.10 (0.0827)H2.70 (0.1063)
C2.20 (0.0866)J2.80 (0.1 102)
D2.30 (0.0906)K1.80 (0.0709)
E2.40 (0.0945)L1.90 (0.0748)
F2.50 (0.0984)−−
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Version 1.11 - 03/16/2010