TOYOTA LAND CRUISER 1996 J80 Workshop Manual

Q07113
SST
Q07114
SST
SST
Bearing
TR−20
−
TRANSFER CENTER DIFFERENTIAL
1996 LAND CRUISER (RM451U)
8. REMOVE REAR TAPER ROLLER BEARING
Using SST and a press, remove the rear taper roller bearing.
SST 09950−00020, 09950 −60010 (09951−00320)
9. REMOVE DIFFERENTIAL REAR CASE
Remove the 12 bolts and differential rear case.
10. REMOVE REAR SIDE GEAR AND THRUST WASHER
11. REMOVE PINION SHAFT, PINION GEAR AND THRUST
WASHER
(a) Remove the straight pin from the pinion shaft.
(b) Remove the pinion shaft, 2 pinion gears and thrust wash-
ers.
(c) Remove the front side gear and thrust washer.
12. REMOVE LOW GEAR
Using a plastic hammer, tap and remove the low gear.
NOTICE:
Be careful not to damage the low gear.
13. REMOVE NEEDLE ROLLER BEARING
(a) Using a screwdriver, remove the snap ring.
(b) Using SST and a hammer, remove the needle roller bear-
ing from the differential rear case.
SST 09223 −00010, 09950 −60010 (09951 −00400),
09950 −70010 (09951 −07150)
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TR0BD−01
Q07115
SSTStamp
TF1012
TF0913
TF0917
−
TRANSFER CENTER DIFFERENTIAL
TR−21
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing
to the differential rear case.
SST 09612−24014 (09612 −10050)
HINT:
Install the bearing to the differential rear case, taking care that
its stamped side comes in contact with SST.
(b) Install the snap ring.
2. INSTALL LOW GEAR
(a) Clean the contact surface of the differential case.
(b) Heat the low gear in boiling water.
(c) Carefully remove the low gear from the water.
(d) After the moisture on the low gear has completely evapo- rated, quickly install the low gear to the differential case.
3. INSTALL PINION SHAFT, PINION GEAR AND THRUST
WASHER
(a) Install the front side gear and thrust washer to the differ- ential front case.
(b) Install the pinion shaft, 2 pinion gears and thrust washers
to the differential front case.
(c) Using a dial indicator, measure the front case backlash.
HINT:
Push the pinion shaft. Minimum backlash: 0.05 mm (0.0020 in.)
If the backlash is not within the specification, replace the thrust
washer with one of the correct size and reinstall the thrust wash-
er.
Thickness mm (in.)Thickness mm (in.)
1.70 (0.0669)2.45 (0.0965)
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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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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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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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