Page 2977 of 3115
F05257
N´m (kgf´cm, ft´lbf)
: Specified torque
Non-reusable part
Precoated part
Side Gear Thrust
WasherSide Gear
Pinion Gear Thrust Washer
Pinion Gear
Spider Adjusting Nut
Bearing
47 (480, 35)
RH Differential Case
x8
Ring Gear
Bearing SpacerBearing
Plate WasherDrive PinionLH Differential Case
137 (1,400, 101)
x12
Companion Flange
Dust Deflector
Oil Seal
Oil Slinger
BearingDifferential Carrier
Bearing Cap
13 (130, 10)
Adjusting Nut Lock
83 (850, 61)
See page SA-107
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA-99
2049 Author: Date:
2004 LAND CRUISER (RM1071U)
Page 2978 of 3115

SA15O-09
W00493
30 mm
(1.18 in.)
F05201
F05202
SA2446
SA-102
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2052 Author: Date:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. SET DIFFERENTIAL CARRIER TO OVERHAUL
STAND, ETC.
2. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the vertical and lateral runout of
the companion flange.
Maximum runout: 0.10 mm (0.0039 in.)
If the runout is greater then the maximum, replace the compan-
ion flange.
3. CHECK RING GEAR RUNOUT
Using a dial indicator, while holding the drive pinion flange,
measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than the maximum, replace the ring gear.
4. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
HINT:
Perform the measurements at 3 or more positions around the
circumference of the ring gear.
If the backlash is not within the specified value, adjust the side
bearing preload or repair as necessary.
5. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the drive pinion preload using
the backlash of the drive pinion and ring gear.
Preload (at starting):
0.64 - 0.92 N´m (6.5 - 9.4 kgf´cm, 5.7 - 8.1 in.´lbf)
Page 2979 of 3115
SA2448
SST
R13166
SST
SA2348
SST
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA-103
2053 Author: Date:
2004 LAND CRUISER (RM1071U)
6. CHECK TOTAL PRELOAD
Using a torque wrench, measure the total preload with the teeth
of the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus
0.38 - 0.63 N´m (3.9 - 6.5 kgf´cm, 3.3 - 5.6 in.´lbf)
If necessary, disassemble and inspect the differential.
7. CHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA-107)
8. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake the nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330-00021
(c) Using SST, remove the companion flange.
SST 09950- 30012 (09951- 03010, 09953- 03010,
09954-03010, 09955-03030, 09956-03040)
9. REMOVE OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal from the differential carrier.
SST 09308-10010
(b) Remove the oil slinger.
Page 2980 of 3115

Z00641
SST
F05203
Matchmarks
Z06911
SST
F05439
Front: Rear: SA-104
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2054 Author: Date:
2004 LAND CRUISER (RM1071U)
10. REMOVE FRONT BEARING
Using SST, remove the front bearing from the drive pinion.
SST 09556-22010
If the front bearing is damaged or worn, replace the bearing.
11. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 2 bolts and adjusting nut locks.
(c) Remove the 4 bolts, 2 bearing caps and adjusting nuts.
HINT:
Tag the disassembled parts to show the location for reassem-
bling.
(d) Remove the differential case with the bearing outer races
from the carrier.
HINT:
Tag the disassembled parts to show the location for reassem-
bling.
12. REMOVE DRIVE PINION AND BEARING SPACER
FROM DIFFERENTIAL CARRIER
(a) Remove the drive pinion with the rear bearing.
(b) Remove the bearing spacer.
13. REMOVE DRIVE PINION REAR BEARING
(a) Using SST and a press, remove the rear bearing from the
drive pinion.
SST 09950-00020
HINT:
If the drive pinion or ring gear is damaged, replace them as a
set.
(b) Remove the plate washer from the drive pinion.
14. REMOVE FRONT AND REAR BEARING OUTER
RACES
Using a brass bar and hammer, remove the outer races.
Page 2981 of 3115

F05204
Matchmarks
F05205
F05206
SST
F05190
Matchmarks
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA-105
2055 Author: Date:
2004 LAND CRUISER (RM1071U)
15. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 ring gear set bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the differential case.
16. CHECK DIFFERENTIAL CASE RUNOUT
(a) Place the bearing outer races on their respective bear-
ings. Check that the right and left outer races are not inter-
changed.
(b) Install the differential case in the differential carrier.
(c) Tighten the adjusting nut just to where there is no play in
the bearing.
(d) Align the matchmarks on the bearing cap and differential
carrier.
(e) Install and uniformly tighten the 4 bearing cap bolts a little
at a time.
(f) Using a dial indicator, measure the differential case run-
out.
Maximum case runout: 0.04 mm (0.0016 in.)
(g) Remove the differential case.
17. REMOVE SIDE BEARINGS FROM DIFFERENTIAL
CASE
Using SST, remove the 2 side bearings from the differential
case.
SST 09950-00020, 09950-00030,
09950-4001 1 (09957-04010),
09950-60010 (09951-00480)
18. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the RH and LH differential cases.
(b) Remove the 8 bolts uniformly, a little at a time.
(c) Using a plastic hammer, separate the RH and LH differen-
tial cases.
(d) Remove the 2 side gear thrust washers, 2 side gears, spi-
der, 4 pinion gears and pinion gear thrust washers.
Page 2982 of 3115
SA15R-1 1
SA-1 16
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2066 Author: Date:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-100).
HINT:
After installation, fill the differential with hypoid gear oil (See page SA-95), fill the brake reservoir with brake
fluid, bleed the brake system (See page BR-4), check for leaks and check the ABS speed sensor signal (See
page DI-505).
Page 2983 of 3115

SA15Q-12
SA0510
F05191
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA-107
2057 Author: Date:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:
Using a shop rag, clean off any foreign object from the
parts.
Apply all of the sliding and rotating surfaces with hypoid
gear oil.
1. MEASURE SIDE GEAR BACKLASH
(a) Install the 2 thrust washers to the side gears.
(b) Install the side gear to the differential case.
(c) Install the 4 pinion gears and thrust washers to the spider.
(d) Install the spider assembly to the differential case.
HINT:
Install the spider to the differential case tightly.
(e) Using a dial indicator, measure the side gear backlash
holding the side gear and spider.
Backlash: 0.02 - 0.15 mm (0.0008 - 0.0059 in.)
HINT:
Measure at all 4 locations.
Measure the backlash at the RH and LH differential
cases.
If the backlash is not within the specified value, install a thrust
washer of a different thickness.
Thrust washer thickness:
Thickness mm (in.)Thickness mm (in.)
1.55 (0.061)1.85 (0.073)
1.60 (0.063)1.90 (0.075)
1.65 (0.065)1.95 (0.077)
1.70 (0.067)2.00 (0.079)
1.75 (0.069)2.05 (0.081)
1.80 (0.071)2.10 (0.083)
2. ASSEMBLE DIFFERENTIAL CASE
(a) Reinstall the spider to the differential case.
HINT:
Install the spider to the differential case tightly.
Page 2984 of 3115

F05190
Matchmarks
F05192
SST
F05193
SST
SST
SA1143
Boiling Water
F05204
Matchmarks
SA-108
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2058 Author: Date:
2004 LAND CRUISER (RM1071U)
(b) Align the matchmarks and assemble the RH and LH dif-
ferential cases.
(c) Tighten the 8 bolts uniformly, a little at a time.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
3. INSTALL SIDE BEARINGS
(a) Using SST and a press, install the RH side bearing on the
differential case.
SST 09710-30050, 09950-70010 (09951-07100)
(b) Using SST and a press, install the LH side bearing on the
differential case.
SST 09710- 30050, 09950- 60010 (09951- 00480),
09950-70010 (09951-07100)
4. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the threads of the bolts and differential case with
the white gasoline.
(b) Clean the contact surfaces of the differential case and
ring gear.
(c) Heart the ring gear to about 100 °C (212 °F) in boiling wa-
ter.
(d) Carefully take the ring gear out of the boiling water.
(e) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(f) Align the matchmarks on the ring gear and differential
case.
(g) Temporarily install the 12 set bolts.
(h) After the ring gear cools down enough, torque the 12 set
bolts to which thread lock has been applied.
Thread lock:
Part No. 08833-00100, THREE BOND 1360 K
or equivalent
Torque: 137 N´m (1,400 kgf´cm, 101 ft´lbf)