Diff lock TOYOTA LAND CRUISER 1996 J80 Repair Manual

SA2437Matchmarks
R08254
SST
Z06911
SST
SA2424
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−83
1996 LAND CRUISER (RM451U)
15. w/ DIFFERENTIAL LOCK:
REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Place matchmarks on the bearing cap and dif ferential car-
rier.
(b) Remove the 4 bolts and 2 bearing caps.
(c) Using SST, remove the plate washers. SST 09504−22011
HINT:
Measure the plate washer thickness and note it.
(d) Remove the differential case with the side bearing outer races from the differential carrier.
HINT:
Tag the bearing outer races to show the location for reassembly.
16. REMOVE DRIVE PINION AND BEARING SPACER FROM DIFFERENTIAL CARRIER
(a) Remove the drive pinion with the rear bearing.
(b) Remove the bearing spacer.
17. 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 are damaged, replace them as
a set.
(b) Remove the plate washer from the drive pinion.
18. REMOVE FRONT AND REAR BEARING OUTER
RACES
Using a brass bar and hammer, remove the outer races.
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SA2464
SA−84
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
19. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 ring gear set nuts and bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the differential case.
20. CHECK DIFFERENTIAL CASE RUNOUT
(a) Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in
the bearing.
(b) Using a dial indicator, measure the differential case run- out.
Maximum case runout: 0.07 mm (0.0028 in.)
(c) Remove the differential case.
21. w/o DIFFERENTIAL LOCK: REMOVE SIDE BEARINGS FROM DIFFERENTIAL
CASE
Using SST, remove the 2 side bearings from the differential
case. SST 09950 −40010 (09951 −04010, 09952 −04010,
09953 −04020, 09955 −04060, 09957 −04010,
09958 −04010), 09950−60010 (09951 −00480)
22. w/ DIFFERENTIAL LOCK:
REMOVE SIDE BEARINGS FROM DIFFERENTIAL
CASE
(a) Using SST, remove the side bearing (ring gear side). SST 09950 −40010 (09951 −04010, 09952 −04010,
09953 −04020, 09955 −04060, 09957 −04010,
09958 −04010), 09950−60010 (09951 −00480)
HINT:
Fix the claws of SST to the notches in the differential case.
(b) Using SST, 4 bolts and a press, remove the side bearing (cover side).
SST 09550−10012 (09557 −10010),
09950 −70010 (09951 −07150)
HINT:
Fix the claws of SST to the notches in the differential case.
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SA2475
SST
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−85
1996 LAND CRUISER (RM451U)
23. w/o DIFFERENTIAL LOCK:
DISASSEMBLE DIFFERENTIAL CASE
(a) Remove the pinion shaft pin and washer.
(b) Remove these parts from the differential case:
Pinion shaft
2 Pinion gears
2 Pinion gear thrust washers
2 Side gears
2 Side gear thrust washers
24. w/ DIFFERENTIAL LOCK: DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the case and cover.
(b) Using a torx socket wrench, remove the 5 set bolts and 3
pinion shaft pins.
(c) Using the 2 cover installation bolts, separate the cover and case.
(d) Remove these parts from the differential case:
2 Side gears
2 Side gear thrust washers
4 Pinion gears
4 Pinion thrust washers
3 Pinion shafts
Pinion shaft holder
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SA0510
SA1VJ−04
Z06893
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−87
1996 LAND CRUISER (RM451U)
REASSEMBLY
1. w/o DIFFERENTIAL LOCK:
ASSEMBLE DIFFERENTIAL CASE
(a) Apply all of the sliding and rotating surfaces with gear oil.
(b) Install the 2 thrust washers and side gears. Using the table below, select the thrust washers which will
ensure that the backlash is within the specification.
Try to select washers of the same size for both sides.
Backlash: 0.02 − 0.20 mm (0.0008−0.0079 in.)
Thrust washer thickness
Thickness mm (in.)Thickness mm (in.)
1.60 (0.063)1.90 (0.075)
1.75 (0.069)2.05 (0.081)
(c) Install the side gears with the side gear thrust washers,
pinion gears, pinion gear thrust washers and pinion shaft.
HINT:
Align the hole for the pinion shaft and differential case hole.
(d) Using a dial indicator, measure the side gear backlash with holding the one pinion gear toward the case.
Backlash: 0.02 − 0.20 mm (0.0008 − 0.0079 in.)
If the backlash is not within the specification, install a thrust
washer of different thickness.
(e) Install the pinion shaft pin and washer.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
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SA0510
R08274
R08276
R13246
SA−88
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
2. w/ DIFFERENTIAL LOCK:
MEASURE SIDE GEAR BACKLASH
(a) Apply all of the sliding and rotating surfaces with gear oil.
(b) Install the thrust washer to the side gear.
(c) Install the thrust washer to the pinion gear.
(d) Install the side gear into the case.
(e) Install the holder into the case.
(f) Install the 4 pinion gears with the thrust washers.
(g) Align the pinion shaft hole and case pinion shaft pin hole,
and install the pinion shaft.
(h) Install the side gear to the cover.
(i) Align the matchmarks and install the case and cover.
(j) Using a torx socket wrench, torque the 5 bolts and 3 pin-
ion shaft pins.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(k) Using a dial indicator, with holding the side gear and mea- sure the backlash.
Backlash: 0.02 − 0.20 mm (0.0008 − 0.0079 in.)
HINT:
Measure at all 4 locations.
If the backlash is not within the specification, install the thrust
washer of a different thickness. Thrust washer thickness
Thickness mm (in.)Thickness mm (in.)
1.60 (0.063)1.90 (0.075)
1.75 (0.069)2.05 (0.081)
(l) After measuring backlash, remove the 5 set bolts and 3pinion shaft pins.
3. w/ DIFFERENTIAL LOCK: ASSEMBLE DIFFERENTIAL CASE
(a) Clean the thread of the bolts, pinion shaft pins, case and
cover with the white gasoline.
(b) Coat the threads of the bolts and pinion shaft pins with adhesive.
Adhesive: Part No. 08833 −00070, THREE BOND 1324
or equivalent
(c) Align the matchmarks, install the case and cover.
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SA1143
Boiling Water
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−89
1996 LAND CRUISER (RM451U)
(d) Using a torx socket wrench, torque the 5 bolts and 3 pin-
ion shaft pins.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
4. INSTALL SIDE BEARINGS
(a) w/o Differential lock: Using SST and a press, install the 2 side bearings on the
differential case.
SST 09315−00022, 09550 −10012 (09558−10010)
(b) w/ Differential lock:
Using SST and a press, install the 2 side bearings on the
differential case.
SST 09550−60010, 09550 −10012 (09558−10010)
5. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and ring gear.
(b) Heat the ring gear to about 100° C (212°F) in boiling wa-
ter.
(c) Carefully remove the ring gear from the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(e) Align the matchmarks on the ring gear and differential case.
(f) Temporarily install the set bolts and nuts so that the bolt
holes in the ring gear and differential case are not misa-
ligned.
NOTICE:
Install the bolts so that the tapered part of the bolt is on the
ring gear side. The ring gear set nuts should not tighten un-
til the ring gear has cooled sufficiently.
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SA2450
SST
SA2446
R08261
R08262
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−91
1996 LAND CRUISER (RM451U)
(d) Adjust the drive pinion preload by tightening the compan-
ion flange nut.
Using SST to hold the flange, tighten the nut.
SST 09330−00021
NOTICE:
Coat the nut and screw of the drive pinion with gear oil. As
there is no spacer, tighten 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 − 2.0 N·m (13 − 20 kgf·cm, 11.3 − 17.4 in.·lbf)
Reused bearing
0.7 − 1.0 N·m (7 − 10 kgf·cm, 6.1 − 8.7 in.·lbf)
HINT:
Measure the total preload after first turning the bearing clock-
wise and counterclockwise several times to make the bearing
smooth.
10. w/o DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the 2 bearing outer races on their respective bear- ings. Make sure that the left and right outer races are not
interchanged.
(b) Install the case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
11. w/ DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the 2 bearing outer races on their respective bear- ings. Make sure that the left and right races are not inter-
changed.
(b) Install the assembled plate washer onto the side bearing.
(c) Install the differential case in the carrier.
(d) Make the plate washer and bearing smooth by tapping on
the ring gear with a plastic hammer.
HINT:
If it is difficult to install the differential case into the carrier, re-
place the plate washer with a thinner one.
However, select a plate washer that allows no clearance be-
tween it and the carrier.
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R08263
R08264
R08265
SA−92
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
12. w/ DIFFERENTIAL LOCK:
ADJUST RING GEAR BACKLASH
(a) Using a dial indicator, with holding the side bearing of the
ring gear side and measure the backlash.
Backlash (reference): 0.15 mm (0.0059 in.)
(b) Select a case cover side plate washer using the backlash
as reference.

Side plate washer thickness
(c) Select a ring gear side plate washer of a thickness which
eliminates any clearance between the plate washer and
carrier.
(d) Remove the 2 plate washers and differential carrier.
(e) Install the plate washer into the lower part of the carrier.
(f) Place the plate washer onto the dif ferential case together
with the outer race, and install the differential case with
the outer race into the carrier.
(g) Using a plastic hammer, make the washer and bearing smooth by tapping the ring gear.
(h) Using a dial indicator, measure the ring gear backlash. Backlash: 0.15 − 0.20 mm (0.0059 − 0.0079 in.)
If it is not within the specification, adjust it by either increasing
or decreasing the number of washers on both sides by an equal
amount.
HINT:
There should be no clearance between the plate washer and
case.
Ensure that there is ring gear backlash.
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RA0090
R08269
SST
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−93
1996 LAND CRUISER (RM451U)
13. w/ DIFFERENTIAL LOCK:
ADJUST SIDE BEARING PRELOAD
(a) After adjustment with the backlash as reference, remove
the ring gear side plate washer.
(b) Using a micrometer, measure the thickness of the re- moved plate washer.
(c) Install a new thicker washer of 0.06 − 0.09 mm (0.0024 −
0.0035 in.) than the washer removed.
HINT:
Select a washer which can be pressed in 2/3 of the way with fin-
ger.
(d) Using SST, tap in the plate washer. SST 09504−22010
(e) Align the matchmarks on the cap and carrier.
(f) Tighten the 4 bearing cap bolts to the specified torque. Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
(g) Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.15 − 0.20 mm (0.0059 − 0.0079 in.)
If it is not within the specification, follow the procedure listed be-
low.
If backlash is greater than the specification:
Replace the cover side washer with a thicker washer. When do-
ing so replace the ring gear side plate washer with one having
a thickness equalling the amount the cover side plate washer
thickness was decreased.
If backlash is less than specification:
Replace the cover side washer with a thicker washer. When do-
ing so, replace the ring gear side plate washer with one having
a thickness equalling the amount the cover side plate washer
thickness was increased.
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Z06953SST
SA2444
SA−94
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
14. w/o DIFFERENTIAL LOCK:
INSTALL ADJUSTING NUTS
Install the 2 adjusting nuts on the carrier, making sure the nuts
are threaded properly.
15. w/o DIFFERENTIAL LOCK: INSTALL BEARING CAPS
Align the matchmarks on the cap and carrier. Screw in the 2
bearing cap bolts 2 or 3 turns and press down the bearing cap
by hand.
HINT:
If the bearing cap does not fit tightly on the carrier , the adjusting
nuts are not threaded properly.
Reinstall the adjusting nuts if necessary.
16. w/o DIFFERENTIAL LOCK: ADJUST SIDE BEARING PRELOAD
(a) Torque the 4 bearing cap bolts to the specified torque, then loosen them to the point where the adjusting nuts
can be turned by SST.
SST 09504−00011
Torque:78 N·m (800 kgf·cm, 58 ft·lbf)
(b) Fully tighten the 4 bearing cap bolts by hand.
(c) Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008
in.).
(d) With turning the ring gear, use the SST to fully tighten the
adjusting nut on the drive pinion side. After the bearings
as settled, loosen the adjusting nut on the drive pinion
side.
(e) Place a dial indicator on the top of the adjusting nut on the ring gear side.
(f) Adjust the side bearing for zero preload by tightening the
other adjusting nut until the pointer on the indicator be-
gins to move.
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