Diff lock TOYOTA LAND CRUISER 1996 J80 Owner's Manual

−
PREPARATION SUSPENSION AND AXLE
PP−43
92
Author: Date:
1996 LAND CRUISER (RM451U)
09504−00011Differential Side Bearing
Adjusting Nut WrenchFront differential
Rear differential
09504−22011Differential Side Bearing
ReplacerRear differential
09506−35010Differential Drive Pinion Rear
Bearing ReplacerRear differential
Rear suspension
09509−25011Rear Axle Bearing Lock Nut
WrenchRear axle
09517−36010Rear Axle Shaft Oil Seal
Replacer −Rear axle
09550−10013Replacer Set ”B”Rear differential
Rear suspension
(09553−10010)Differential Side Bearing
Replacer
(09557−10011)Differential Drive Pinion
Front Bearing Replacer
09550−60010Differential Side Bearing
ReplacerRear differential
09556−22010Drive Pinion Front Bearing
RemoverFront differential
Rear differential
09605−60010Steering Knuckle Bearing Cup
Replacer−Front axle
09606−60020Steering Knuckle Bearing RemoverFront axle
09607−60020Front Wheel Adjusting Nut WrenchFront axle
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

PP3KO−01
PP−48
−
PREPARATION SUSPENSION AND AXLE
1996 LAND CRUISER (RM451U)
RECOMMENDED TOOLS
09025−00010Small Torque Wrench (30 kgf −cm)Front differential
Rear differential
09031−00030Pin Punch .Front differential
09040−00011Hexagon Wrench Set .Front differential
(09043−20060)Socket Hexagon Wrench 6.
09044−00020Torx Socket E10 .Rear differential
09082−00050TOYOTA Electrical Tester Set.Differential locking system
09905−00012Snap Ring No.1 Expander .Front axle
Front differential
09905−00013Snap Ring Pliers .Front axle
Front differential
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

PP2YE−01
PP−50
−
PREPARATION SUSPENSION AND AXLE
1996 LAND CRUISER (RM451U)
LUBRICANT
ItemCapacityClassification
Differential oil
Front w/o Dfferential lock w/ Dfferential lock
Rear
2.80 liters (2.9 US qts, 2.5 lmp. qts)
2.65 liters (2.8 US qts, 2.3 lmp. qts)
3.25 liters (3.4 US qts, 2.9 lmp. qts)
Hypoid gear oil API GL− 5
Above − 18°C (0° F) SAE 90
Below − 18°C (0° F) SAE 80W− 90 or 80W
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

PP2YF−02
−
PREPARATION SUSPENSION AND AXLE
PP−51
1996 LAND CRUISER (RM451U)
SSM (Special Service Materials)
08826−00090Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)Front differential
Rear differential
Differential locking system
08833−00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalentFront differential
Rear differential
Differential locking system
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

RS0OZ−02
−
SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG
RS−1
1100
Author: Date:
1996 LAND CRUISER (RM451U)
SRS AIRBAG
PRECAUTION
NOTICE:
The LAND CRUISER is equipped with an SRS , which comprises a driver airbag \
and a front pas-
senger airbag. Failure to carry out service operations in the correct sequence could cause the
SRS to unexpectedly deploy during servicing, possibly leading to a serio\
us accident. Further,
if a mistake is made in servicing the SRS, it is possible the SRS may fail to\
operate when re-
quired. Before performing servicing (including removal or installation \
of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedure
described in the repair manual.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the mos\
t impor-
tant source of information when troubleshooting. When troubleshooting th\
e SRS, always in-
spect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, and airbag sensor assembly should be inspected (See pages
RS−9 , RS−23 and RS−34 )
Never use SRS parts from another vehicle. When replacing parts, replace them with \
new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly , or air-
bag sensor assembly in order to reuse it.
If the steering wheel pad, front passenger airbag assembly or airbag sen\
sor assembly have
been dropped, or if there are cracks, dents or other defects in the case, br\
acket or connector,
replace them with new ones.
Use a volt/ohmmeter wi th high impedance (10 k Ω/V minimum) for troubleshooting the system’s
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions on the notices.
After work on the SRS is completed, check the SRS warning light (See pa\
ge DI−240).
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
CAUTION:
Work must be started after 90 seconds from the time the ignition switch is t\
urned to the ”LOCK”
position and the negative ( −) terminal cable is disconnected from the battery.
(The SRS is equipped with a back− up power source so that if work is started within 90 seconds
of disconnecting the negative ( −) terminal cable of the battery, the SRS may be deployed.)
When the negative (−) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record o\
f the contents mem-
orized in the audio memory system. When work is finished, reset the audio syst\
ems as they
were before and adjust the clock. To avoid erasing the memory of each memory system, never
use a back−up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the senso\
r during
repairs.
Do not expose the steering wheel pad, front passenger airbag assembly, or airbag sensor as-
sembly directly to hot air or flames.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA1U7−01
−
SUSPENSION AND AXLE TROUBLESHOOTING
SA−1
858
Author: Date:
1996 LAND CRUISER (RM451U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
(w/ Differential locking system):
Check that center differential lock mode is set.
When switching differential Free↔Lock, the indicator lamp will blink if the gears of the differen-
tial lock sleeve are not meshed. If this occurs, when the tires are rotated \
to apply differential
power to the differential, the differential locks and the indicator lamp\
light up.
SymptomSuspect AreaSee page
Wander/ pulls
1. Tires: worn or improperly inflated
2. Wheel alignmemt: incorrect
3. Steering linkage: loosen or worn
4. Hub bearings: loosen or worn
5. Steering gear: out of adjustment or brokenSA−3
SA−4
SR−47 SA−8
SR−41
Bottoming
1. Vehicle: overloaded
2. Spring weak
3. Shock absorber: worn out−
SA−49
SA−49
Sways/ pitches
1. Tires: worn or improperly inflated
2. Stabilizer bar: bent or broken
3. Shock absorber: worn outSA−3
SA−60
SA−49
Front wheel shimmy
1. Tires: worn or improperly inflated
2. Wheels: out of balance
3. Shock absorber: worn out
4. Wheel alignmemt: incorrect
5. Hub bearings: loosen or worn
6. Steering linkage: loosen or worn
7. Steering gear: out of adjustment or brokenSA−3
SA−3
SA−49 SA−3
SA−7
SR−45
SR−38
Abnormal tire wear
1. Tires: worn or improperly inflated
2. Wheel alignmemt: incorrect
3. Suspension parts: worn out
4. Shock absorber: worn outSA−3
SA−3 −
SA−49
Noise in front dif ferential
1. Oil level: low or wrong grade
2. Excessive backlash between pinion and ring gear
3. Ring, pinion ro side gears: worn or chipped
4. Pinion shaft bearing: worn
5. Side bearing: worn
6. Differential bearing: loosen or wornSA−21
SA−29
SA−29
SA−29
SA−29
SA−29
Oil leak from front dif ferential
1. Oil level: too high or wrong grade
2. Drive pinion oil seal: worn or damaged
3. Side gear oil seal: worn or damaged
4. Companion flange: loosen or damaged
5. Side gear shaft: damagedSA−21
SA−29
SA−29
SA−29
SA−29
Noise in rear axle
1. Oil level: low or wrong grade
2. Excessive backlash between pinion and ring gear
3. Ring, pinion ro side gears: worn or chipped
4. Pinion shaft bearing: worn
5. Axle shaft bearing: worn
6. Differential bearing: loosen or wornSA−73
SA−87
SA−87
SA−87
SA−87
SA−87
Oil leak from rear axle1. Oil seal: worn or damaged
2. Rear axle housing: crackedSA−73
−
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA−2
−
SUSPENSION AND AXLE TROUBLESHOOTING
859
Author: Date:
1996 LAND CRUISER (RM451U)
Oil leak from rear dif
ferential
1. Oil level: too high or wrong grade
2. Oil seal: worn or damaged
3. Companion flange: loosen or damagedSA−73
SA−73
SA−87
Indicator lights do not light up
1. Fusible link: blown
2. GAUGE fuse: blown
3. Bulb: burned out
4. Wiring or ground: faultyBE−9
BE−9
BE−32 −
Indicator lights do not light up
(Diff. lock control switch RR or FR RR position)
1. DIFF fuse: blown
2. Diff. lock control switch: faulty
3. Diff. lock ECU: faulty
4. Wiring or ground: faultyBE−9
SA−101
SA−101 −
Differential lock does not operate
1. Diff. lock position switch: faulty
2. Diff. lock actuator: faulty
3. Diff. lock ECU: faulty
4. Differential carrier (Diff. lock): faulty
5. Wiring or ground: faultySA−101
SA−101
SA−101
SA−101−
After differential lock, lock not release
When vehicle speed is higher than approx. 8 km/h (5mph)1. Speed sensor: faulty
2. Diff. lock ECU: faulty
3. Wiring or ground: faultyBE−32
SA−101 −
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA1960
SST
RA1072
Filler Hole
Oil
0 − 5 mm (0 − 0.20 in.)
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL REAR OIL SEAL
SA−23
1996 LAND CRUISER (RM451U)
(c) Apply light coat of gear oil on threads of a new companion
flange nut.
(d) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 196 N·m (2,000 kgf·cm, 145 ft·lbf)
14. ADJUST DRIVE PINION PRELOAD (See page SA−36 )
15. STAKE DRIVE PINION NUT
16. INSTALL FRONT PROPELLER SHAFT (See page PR−5 )
17. FILL DIFFERENTIAL WITH GEAR OIL Torque: 49 N·m (500 kgf·cm, 39 ft·lbf)
Oil type: Hypoid gear oil API GL −5
Recommended oil viscosity:
Above −18°C (0° F) SAE 90
Below −18°C (0° F) SAE 80W−90 or 80W
Capacity:
w/o Differential lock:
2.80 liters (2.9 US qts, 2.5 Imp. qts)
w/ Differential lock:
2.65 liters (2.8 US qts, 2.3 Imp. qts)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

W00530
w/o Differential LockSide Gear Thrust WasherPinion Gear
Pinion Gear Thrust Washer
 Dust Deflector
Front Bearing Outer Race
 Oil Seal
Companion Flange
Bearing Cap
Differential Carrier

Adjusting Nut Lock Oil Slinger
Differential Case
Drive Pinion
Ring Gear
Side Baring
Straight Pin
Adjusting Nut
 Bearing Spacer


Oil Storage Ring
Outer Race
Outer Race
 Non− reusable part 
Lock Plate
x 10
x 5 Pinion Shaft
Pinion Gear
Pinion Washer
Rear Bearing
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−25
882
Author: Date:
1996 LAND CRUISER (RM451U)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

W00531
w/ Differential LockSide Gear
Thrust Washer
Pinion Gear
Thrust Washer
Outer Race

Oil Seal Companion Flange
Bearing Cap
Differential Carrier
 Adjusting Nut Lock Oil Slinger
Drive Pinion
Ring Gear
Side Baring
Adjusting Nut

Bearing Spacer

Oil Storage Ring
Outer Race
 Non− reusable part

Lock Plate x 8
x 4 
O− Ring
Pinion Washer
Rear Bearing

 Dust Deflector
Front Bearing Outer Race
Adjusting Nut
Sleeve
Spider Side GearLH Differential Case
RH Differential Case
x 8
 Precoated part 
Gasket Indicator Switch
Actuator

Straight Screw Plug
Spring Seat
Compression Spring
Ball

Shaft Retainer Shift Fork Shaft Shift Fork

Slotted Spring Pin
Pinion Gear
SA−26
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
883
Author: Date:
1996 LAND CRUISER (RM451U)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010