Page 3025 of 3115
SA164-10
SA-162
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2112 Author: Date:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-141).
HINT:
After installation, fill the differential with hypoid gear oil for LSD (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 3026 of 3115
SA1DA-04
F05258
RH Case:LH Case:
X
X
F05259
SST
Y SA-150
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2100 Author: Date:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:
When reusing the side gear, thrust washers and clutch
plates, skip the STEP 1.
Using a shop rag, clean off any foreign object from the
parts.
Apply all of the sliding and rotating surfaces with LSD oil.
1. SELECT ADJUSTING SHIM
(a) Measure the RH and LH differential case dimensions ºXº,
as shown in the illustration.
(b) Install the thrust washers and clutch plates on the side
gear.
(c) Using SST to press down the thrust washers and clutch
plates with about pressure of 10 kgf (22 lbf), measure di-
mension ºYº, as shown in the illustration.
SST 09649-17010
(d) Referring to the following selection table on the next
page, select the proper adjusting shim.
Adjust shim thickness =
X - Y - 19.08 mm (0.7511 in.)
Page 3027 of 3115
F05260
46.05 46.06 46.07 46.08 46.09 46.10 46.11 46.12 46.13 46.14 46.15 46.16 46.17 46.18 46.19 46.20 46.21 46.22
26.45
26.46
26.47
26.48
26.49
26.50
26.51
26.52
26.53
26.54
26.55
26.56
26.57
26.58
26.59
26.60
26.61
26.62
26.63
26.64
26.65
26.66
26.67
26.68
26.69
26.70
26.71
26.72
26.73
26.74
26.75
26.76
26.77
26.78
26.79
26.80
26.81
26.82
26.83
26.84
26.85
26.86
26.87
26.88
#: Reassemble another type shim or check the backlash after assembling A shim.
A
#
B
C
D
A + A
A + B
B + B
B + C
C + C
C + D "
X mm
Y mm
u
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
SA-151
2101 Author: Date:
2004 LAND CRUISER (RM1071U)
Page 3028 of 3115
F05260
"
X in.
1.8129
1.0413
Y in.
#: Reassemble another type shim or check the backlash after assembling A shim.
A
#
B
C
D
A + A
A + B
B + B
B + C
C + C
C + D
1.8133 1.8137 1.8141 1.8145 1.8149 1.8153 1.8157 1.8161 1.8165 1.8169 1.8173 1.8181 1.81881.8177 1.8185 1.8192 1.8196
1.0417
1.0421
1.0425
1.0429
1.0433
1.0436
1.0440
1.0444
1.0448
1.0452
1.0456
1.0460
1.0496
1.0499
1.0503
1.0507
1.0515
1.0519
1.0523
1.0527
1.0531
1.0535
1.0539
1.0543
1.0547
1.0551
1.0555 1.0464
1.0468
1.0472
1.0476
1.0480
1.0484
1.0488
1.0492
1.0559
1.0562
1.0566
1.0570
1.0574
1.0578
1.0582 1.0511
u
SA-152
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2102 Author: Date:
2004 LAND CRUISER (RM1071U)
Page 3029 of 3115

W01877
W01878
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
SA-153
2103 Author: Date:
2004 LAND CRUISER (RM1071U)
Adjust shim thickness:
MarkThickness mm (in.)MarkThickness mm (in.)
A0.20 (0.0079)C0.30 (0.0118)
B0.25 (0.0098)D0.35 (0.0138)
2. CHECK SIDE GEAR BACKLASH
(a) Install the thrust washers, clutch plates and adjusting
shim to side gear.
HINT:
Install the adjusting shim with its surface having no oil groove
facing to the differential case side.
(b) Install the side gear to the differential case.
(c) Install the 4 pinion gears and thrust washers to the spider.
(d) Align the spring retainer holes with the straight pins and
install the retainer.
(e) Install the spider to the differential case.
HINT:
Install the spider to the differential case tightly and do not move
the spring retainer.
(f) Using a dial indicator, measure the side gear backlash
while 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, select the ad-
justing shim.
3. ASSEMBLE DIFFERENTIAL CASE
(a) Reinstall the spider to the LH differential case.
HINT:
Install the spider to the LH differential case tightly and do not
move the spring retainer.
(b) Install the compression spring and RH spring retainer.
(c) Install the RH side gear.
(d) Align the matchmarks and assemble the RH and LH dif-
ferential cases.
Page 3030 of 3115

F05192
SST
F05193
SST
SST
SA1143
Boiling Water
F05204
Matchmarks
SA-154
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2104 Author: Date:
2004 LAND CRUISER (RM1071U)
HINT:
Be careful not to drop the side gear.
Check the pinion and side gear alignment.
(e) Tighten the 8 bolts uniformly, a little at a time.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
4. INSTALL SIDE BEARING
(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)
5. 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) Heat 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 has cooled down enough, torque the
12 set bolts to which thread lock has been applied.
Thread lock:
Part No. 08833-00100, THREE BOND 1360K
or equivalent
Torque: 137 N´m (1,400 kgf´cm, 101 ft´lbf)
Page 3031 of 3115

F05194
F05804
SSTSST Front: Rear:
SA3102
SST
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
SA-155
2105 Author: Date:
2004 LAND CRUISER (RM1071U)
6. CHECK RING GEAR 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 onto the carrier and tighten the
adjusting nut just to where there is no play in the bearings.
(c) Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 in.)
(d) Remove the differential case.
7. INSTALL DRIVE PINION FRONT AND REAR BEARING
OUTER RACES
(a) Using SST and a press, install the front bearing outer
race.
SST 09950-60020 (09951-00710),
09950-70010 (09951-07150)
(b) Using SST and a press, install the rear bearing outer race.
SST 09950-60020 (09951-00890),
09950-70010 (09951-07150)
8. INSTALL DRIVE PINION REAR BEARING
(a) Install the plate washer on the drive pinion.
HINT:
First fit a washer with the same thickness as the washer which
was removed, then after checking the tooth contact pattern, re-
place the washer with one of a different thickness if necessary.
(b) Using SST and a press, install the rear bearing onto the
drive pinion.
SST 09506-35010
9. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion and front bearing.
HINT:
Assemble the spacer and oil seal after adjusting the gear con-
tact pattern.
(b) Install the oil slinger.
Page 3032 of 3115

R13414
SST
SA2450
SST
SA2446
F05195
SA-156
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2106 Author: Date:
2004 LAND CRUISER (RM1071U)
(c) Install the companion flange with SST.
SST 09950- 30012 (09951- 03010, 09953- 03010,
09954-03010, 09955-03030, 09956-03040)
(d) Using SST to hold the flange and adjust the drive pinion
preload by tightening the companion flange nut.
SST 09330-00021
NOTICE:
Coat the nut and screw of the drive pinon with gear oil.
As there is no spacer, tighten the nut a little at a time,
being careful not to overtighten.
(e) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing
1.3 - 1.8 N´m (13 - 19 kgf´cm, 11.5 - 15.9 in.´lbf)
Reused bearing
0.64 - 0.92 N´m (6.5 - 9.4 kgf´cm, 5.7 - 8.1 in.´lbf)
HINT:
Measure the total preload after turning the bearing clockwise
and counterclockwise several times to make the bearing
smooth.
10. INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the 2 bearing outer races on their respective bear-
ings. Make sure that the right and left outer races are not
interchanged.
(b) Install the differential case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
11. INSTALL ADJUSTING NUTS
Install the 2 adjusting nuts on the carrier, making sure the nuts
are engaged properly.