1996 TOYOTA LAND CRUISER transfer

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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TR−24
−
TRANSFER CENTER DIFFERENTIAL
1996 LAND CRUISER (RM451U)
(b) Using a snap ring expander, install a new snap ring.
16. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE (See page TR−19 )
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TR0BE−01
Z18836
Front Output Shaft
Dust Deflector
 Oil Seal Housing Ball Bearing

Snap Ring Drive Clutch Hub

Snap Ring
 Snap Ring
−
TRANSFER FRONT EXTENSION HOUSING
TR−25
835
Author: Date:
1996 LAND CRUISER (RM451U)
FRONT EXTENSION HOUSING
COMPONENTS
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Version 1.11 - 03/16/2010

TR0BF−01
Q07133
SST
TF0938
TF0940
SST
TR−26
−
TRANSFER FRONT EXTENSION HOUSING
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE DRIVE CLUTCH HUB
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST, remove the drive clutch hub. SST 09950−40010
2. REMOVE FRONT OUTPUT SHAFT
Using a plastic hammer, drive out the front output shaft.
3. REMOVE DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector. SST 09950−00020
(b) Using a screwdriver and hammer, tap the dust deflector
and remove it from the extension housing.
4. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal from the front extension
housing.
5. REMOVE BALL BEARING
(a) Using a screwdriver, remove the snap ring.
(b) Using SST and a press, remove the ball bearing. SST 09316−60011 (09316 −00011, 09316−00071)
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TR0BG−01
TF0967
SST
TF0943
SST
TF0939
TF0945
SST
−
TRANSFER FRONT EXTENSION HOUSING
TR−27
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL DUST DEFLECTOR
(a) Using SST and a press, install a new dust deflector to the
front extension housing.
SST 09223−15020, 09950 −70010 (09951−07150)
(b) Using SST and a press, install a new dust deflector to the
front output shaft.
SST 09316−20011, 09316 −60011 (09316−00011)
2. INSTALL BALL BEARING
(a) Using SST and a press, install the ball bearing to the front
extension housing.
SST 09316−60011 (09316 −00011, 09316−00031)
(b) Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)
A1.7 (0.0669)
B1.8 (0.0709)
(c) Using a screwdriver, install a new snap ring.
3. INSTALL OIL SEAL
Using SST and a hammer, drive in a new oil seal to the front ex-
tension housing.
SST 09316−60011 (09316 −00011, 09316−00061)
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Q00542
SSTSST
TF0933
TR−28
−
TRANSFER FRONT EXTENSION HOUSING
1996 LAND CRUISER (RM451U)
4. INSTALL FRONT OUTPUT SHAFT AND DRIVE
CLUTCH HUB
(a) Using SST and a press, install the front output shaft and
drive clutch hub.
SST 09316−20011, 09316 −60011 (09316−00011,
09316 −00041, 09316 −00071)
(b) Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)
A1.8 (0.0709)
B1.9 (0.0748)
C2.0 (0.0787)
D2.1 (0.0827)
E2.2 (0.0866)
(c) Using a snap ring expander, install a new snap ring.
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TR0BH−01
Q08383
Center Differential Control
Couping Assembly
Snap ring Vehicle Speed sensor
Drive Gear Ball Bearing
 Snap Ring
Snap Ring
Oil Pump Plate
Drive Rotor
Oil Pump Cover
Rear Extension housing
Oil Pump Drive Shaft Ball
Spring 
Screw Plug
Valve Seat

Dust Deflector
 Oil Seal Seal Ring
Rear Output Shaft
 Non− reusable Part
 Precoated part Separator
Driven Rotor
−
TRANSFER REAR EXTENSION HOUSING
TR−29
839
Author: Date:
1996 LAND CRUISER (RM451U)
REAR EXTENSION HOUSING
COMPONENTS
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Brought to you by BirfMark
Version 1.11 - 03/16/2010

TR0BI−01
Q00530
Q08384
Q02549
Q07138
TR−30
−
TRANSFER REAR EXTENSION HOUSING
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE OIL PUMP DRIVE SHAFT
2. REMOVE OIL PUMP COVER
(a) Using a torx socket wrench (T30), remove the 3 screws.
(b) Install the 2 suitable bolts to the pump cover.
(c) Remove the pump cover from the rear extension housing.
3. REMOVE DRIVE ROTOR FROM DRIVEN ROTOR
4. REMOVE DRIVEN ROTOR FROM REAR EXTENSION HOUSING
5. REMOVE SCREW PLUG, SPRING, BALL AND VALVE SEAT
(a) Using a hexagon wrench, remove the screw plug.
(b) Using a magnetic finger, remove the spring, ball and valve
seat from the rear extension housing.
6. REMOVE CENTER DIFFERENTIAL CONTROL COU- PLING ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the coupling assembly from the rear extension housing.
7. REMOVE SEPARATOR AND OIL PUMP PLATE
Remove the 3 bolts, separator and oil pump plate.
8. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the vehicle speed sensor drive gear.
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