1998 TOYOTA LAND CRUISER clutch

ST08D-04
B04550
Dust Protector
B04632
B04551
B04552
(2)(3)
(1) (4)
(5)
ST0948
Magnetic Finger
ST-6
- STARTINGSTARTER
1822 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. REMOVE 2 DUST PROTECTORS
2. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(b) Remove the 2 through bolts.
Torque: 9.3 N´m (95 kgf´cm, 82 in.´lbf)
(c) Pull out the field frame together with the armature from the
magnetic switch assembly.
NOTICE:
At the time of notice, align the protrusion of the field frame
with the groove of the magnetic switch.
(d) Remove the O-ring from the field frame.
HINT:
At the time of assembly, use a new O-ring.
3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY
AND GEAR
(a) Remove the 2 screws.
Torque: 9.3 N´m (95 kgf´cm, 82 in.´lbf)
(b) Remove these parts from the magnetic switch assembly:
(1) Starter housing
(2) Return spring
(3) Idler gear
(4) Bearing
(5) Starter clutch assembly
HINT:
At the time of assembly, apply grease to the return spring and
insert the return spring into the clutch shaft hole.
4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
HINT:
At the time of assembly, apply grease to the steel ball and insert
the steel ball into the clutch shaft hole.

P10588
Ohmmeter
Continuity
S02267
Ohmmeter
(A)(B)
Z00037
ST0019
P21088
Ohmmeter
No Continuity
- STARTINGSTARTER
ST-9
1825 Author
: Date
:
2004 LAND CRUISER (RM1071U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, measure the resistance between shunt
coil terminals (A) and (B).
Resistance:
1.5 - 1.9 W at 20°C (68°F)
If the resistance is not as specified, replace the field frame.
9. INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
Standard length:
15.0 mm (0.591 in.)
Minimum length:
9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Using a pull scale, measure the spring load by pulling the spring
from the brush until they are separated.
Standard spring installed load:
21.5 - 27.5 N (2.2 - 2.8 kgf, 4.8 - 6.2 lbf)
Minimum spring installed load:
12.7 N (1.3 kgf, 2.9 lbf)
If the installed load is less than minimum, replace the brush
springs.
11. INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch
assembly for wear or damage.
If any damage is found, replace the gear or clutch assembly,
and also check the drive plate ring gear for wear or damage.

P10821
Free
Lock
B04553Terminal CTerminal 50
ContinuityOhmmeter
B04554
Continuity Ohmmeter
Terminal 50
ST-10
- STARTINGSTARTER
1826 Author
: Date
:
2004 LAND CRUISER (RM1071U)
13. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear clockwise, and check that it turns freely.
Check that it locks by rotating the pinion gear counterclockwise.
If necessary, replace the clutch assembly.
14. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, replace the magnetic switch.
15. DO HOLD-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch.

ST08H-07
B04543
Terminal 50
Battery
Terminal C
B04544
Battery
Terminal CDisconnect
B04545
Disconnect
Battery
B04546
Terminal 30
Battery
Ammeter Terminal 50 ST-16
- STARTINGSTARTER
1832 Author
: Date
:
2004 LAND CRUISER (RM1071U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid the
coil to be burned-out.
1. DO PULL-IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the pinion gear moves outward.
2. DO HOLD-IN TEST
While connected as above with the pinion gear out, disconnect
the negative (-) lead from terminal C. Check that the pinion gear
remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the starter body. Check
that the pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
shows the specified current.
Specified current:
At 11.5 V: 100 A or less

SA2133
F05801
Z15219
FIPG Width Approx.
1 - 2 mm (0.04 - 0.08 in.)
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
SA-137
2087 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(g) Engage the sleeve with the dog clutch of the differential
case.
(h) Install the 4 bolts.
Torque: 24 N´m (240 kgf´cm, 18 ft´lbf)
28. INSTALL COVER
(a) Clean contacting surfaces of any FIPG material using
gasoline or alcohol.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281
or equivalent
HINT:
Install the cover within 10 minutes after applying FIPG.
(c) Install the cover with the 3 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
29. INSTALL REAR DIFF. LOCK POSITION SWITCH
Install the rear diff. lock position switch with a new gasket.
Torque: 40 N´m (410 kgf´cm, 30 ft´lbf)
30. REMOVE DIFFERENTIAL CARRIER FROM OVER-
HAUL STAND, ETC.

F05173
Pinion Gear Thrust Washer
Pinion Gear
Spider
Spring Retainer#: If the side gear backlash has been adjusted
by TOYOTA dealer, adjusting shims are
installed between the side gear thrust washer
and the differential case.Compression Spring
LH Differential Case


x12
Adjusting Nut
Bearing
Ring Gear
 Bearing Spacer
Bearing
Plate Washer
Drive Pinion
47 (480, 35)
x8
RH Differential
Case
# Adjusting Shim
Clutch Plate
Side Gear Thrust Washer

Companion Flange
 Dust Deflector
Oil Slinger
 Oil Seal
Bearing
Bearing Cap
Differential Carrier
83 (850, 61)
13 (130, 10)
 Adjusting Nut Lock
N´m (kgf´cm, ft´lbf): Specified torque
 Non-reusable part

Precoated part
See page SA-150

Side Gear


137 (1,400, 101)
# SA-140
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2090 Author
: Date
:
2004 LAND CRUISER (RM1071U)

- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
SA-147
2097 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(d) Remove the 2 side gears, 6 side gear thrust washers, 4
clutch plates, 2 spring retainers, compression spring, 4
pinion gears, 4 pinion gear thrust washers and spider
from the differential case.
HINT:

Keep the disassembled parts in order.

If the side gear backlash has been adjusted by TOYOTA
dealer, adjusting shims are installed between the side
gear thrust washer and the differential case.

SA161-04
RA0225
Z15288
R13849
RA0192
SA-148
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2098 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSPECTION
1. REPLACE PARTS THAT ARE DAMAGED OR WORN
HINT:
If replacing the side gear, also replace the thrust washer that
contact with it.
2. INSPECT SIDE GEAR THRUST WASHERS FOR WEAR
OR DAMAGE
Using a micrometer, measure that the contact surface of the
thrust washer is even and check that no bare metal is showing.
Thickness (Reference):
1.97 - 2.06 mm (0.0776 - 0.0811 in.)
If necessary, replace the thrust washer.
HINT:
If replacing the thrust washer, also replace the clutch plate that
contacts with it.
3. INSPECT CLUTCH PLATE FOR WEAR OR DAMAGE
Using a micrometer, measure the contact surface of the clutch
plate and check that there is no abnormal wear.
Thickness (Reference):
1.97 - 2.03 mm (0.0776 - 0.0799 in.)
If necessary, replace the clutch plate.
4. INSPECT COMPRESSION SPRING FREE LENGTH
Using vernier calipers, measure the free length of the spring.
Length (Reference): 32.8 mm (1.291 in.)