TOYOTA LAND CRUISER 1998 Factory Repair Manual

SA14Q-04
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA-59
2009 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-39).
HINT:
After installation, fill the differential with hypoid gear oil (See page SA-35).

SA14P-09
SA1978
SA1976
FA2037
Matchmarks
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA-47
1997 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:

Using a shop rag, clean off any foreign object from the
parts.

Apply all of the sliding and rotating surfaces with hypoid
gear oil.
1. MEASURE SIDE GEAR BACKLASH AND ASSEMBLE
DIFFERENTIAL CASE
(a) Install the 2 side gear thrust washers to the side gears.
(b) Install the 2 side gears to the RH case.
(c) Install the 4 pinion gears and pinion gear thrust washers
to the spider.
(d) Install the pinion gears with the spider to the RH case.
(e) Using a dial indicator, holding the side gear and spider,
measure the side gear backlash,
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
HINT:

Measure at all 4 locations.

Measure the backlash at the RH case and at the LH case.
If the backlash is not within the specification, install a thrust
washer of a different thickness.
Thrust washer thickness
Thickness mm (in.)Thickness mm (in.)
0.9 (0.035)1.2 (0.047)
1.0 (0.039)1.3 (0.051)
1.1 (0.043)-
(f) Align the matchmarks on the LH and RH cases.
(g) Torque the 8 bolts uniformly a little at a time.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)

SA2160
Boiling Water
Z02483
SA2415
SST
SST
SA-48
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
1998 Author
: Date
:
2004 LAND CRUISER (RM1071U)
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and
ring gear.
(b) Heat the ring gear to approx. 100°C (212°F) in boiling wa-
ter.
(c) Carefully take the ring gear out of the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the ring gear and differential case.
(e) Temporarily install 5 new lock plates and 10 bolts so that
the bolt holes in the ring gear and differential case are not
misaligned.
(f) After the ring gear has cooled sufficiently, torque the 10
ring gear set bolts.
Torque: 97 N´m (985 kgf´cm, 71 ft´lbf)
(g) Using a chisel and hammer, stake the 5 lock plates.
HINT:
Stake the claws of the lock plates to fix the bolts. For the claw
contacting the protruding portion of the bolt, stake only the half
of it along the tightening direction.
3. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 side bearings to the differ-
ential case.
SST 09223-15020, 09950-60010 (09951-00480)

F05229
F05212
FRONT REAR
SST
SST
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA-49
1999 Author
: Date
:
2004 LAND CRUISER (RM1071U)
4. CHECK RING GEAR RUNOUT
(a) Place the bearing outer races on their respective bear-
ings. Check that the left and right outer races are not inter-
changed.
(b) Install the assembled plate washers onto the side bear-
ing.
(c) Install the differential case in the differential carrier.
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.
(d) Align matchmarks on the bearing cap and differential car-
rier.
(e) Install and uniformly tighten the 4 bolts a little at a time.
(f) Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 in.)
(g) Remove the differential carrier.
5. 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- 00780), 09950- 70010
(09951-07150)
(b) Using SST and a press, install the rear bearing outer race.
SST 09950- 60020 (09951- 00710), 09950- 70010
(09951-07150)
6. INSTALL DRIVE PINION FRONT BEARING
(a) Install the 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.

SA3102
SST
R13414
SST
SA2450
SST
SA2446
SA-50
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
2000 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(b) Using SST and a press, install the front bearing onto the
drive pinion.
SST 09506-30012
7. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion and rear bearing.
HINT:
Assemble the spacer and oil seal after adjusting the gear con-
tact pattern.
(b) Install the oil slinger.
(c) Using SST, install the companion flange.
SST 09950- 30012, (09951- 03010, 09953- 03010,
09954-03010, 09955-03030, 09956-03020)
(d) Using SST to hold the flange and adjust the drive pinion
preload by tightening the nut.
NOTICE:

Coat the nut and threads of the drive pinion 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
1.0 - 1.6 N´m (10 - 16 kgf´cm, 8.7 - 13.9 in.´lbf)
Reused bearing
0.5 - 0.8 N´m (5 - 8 kgf´cm, 4.3 - 6.9 in.´lbf)
HINT:
Measure the total preload after turning the bearing clockwise
and counterclockwise several times to make the bearing
smooth.
8. INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL
CARRIER
(a) Place the bearing outer races on their respective bear-
ings. Check that the left and right outer races are not inter-
changed.
(b) Install the differential case in the differential carrier.

FA0743
FA0744
F11455
FA0743
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA-51
2001 Author
: Date
:
2004 LAND CRUISER (RM1071U)
9. ADJUST RING GEAR BACKLASH
(a) Install the plate washer on the ring gear back side.
HINT:
Make sure that the ring gear has backlash.
(b) Tap on the ring gear with a plastic hammer so that the
washer fits to the bearing.
(c) Using a dial indicator, measure the side gear backlash
while holding one pinion gear toward the differential case.
Backlash (Reference): 0.13 mm (0.0051 in.)
(d) Select a plate washer for back side ring gear, using the
backlash as reference.

FA0742
FA0752
SA-52
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
2002 Author
: Date
:
2004 LAND CRUISER (RM1071U)
Side plate washer thickness
Thickness mm (in.)Thickness mm (in.)
2.58 (0.1016)3.04 (0.1197)
2.60 (0.1024)3.06 (0.1205)
2.62 (0.1031)3.08 (0.1213)
2.64 (0.1039)3.10 (0.1220)
2.66 (0.1047)3.12 (0.1228)
2.68 (0.1055)3.14 (0.1236)
2.70 (0.1063)3.16 (0.1244)
2.72 (0.1071)3.18 (0.1252)
2.74 (0.1079)3.20 (0.1260)
2.76 (0.1087)3.22 (0.1268)
2.78 (0.1094)3.24 (0.1276)
2.80 (0.1102)3.26 (0.1283)
2.82 (0.1110)3.28 (0.1291)
2.84 (0.1118)3.30 (0.1299)
2.86 (0.1126)3.32 (0.1307)
2.88 (0.1134)3.34 (0.1315)
2.90 (0.1142)3.36 (0.1323)
2.92 (0.1150)3.38 (0.1331)
2.94 (0.1157)3.40 (0.1339)
2.96 (0.1165)3.42 (0.1346)
2.98 (0.1173)3.44 (0.1354)
3.00 (0.1181)3.46 (0.1362)
3.02 (0.1189)3.48 (0.1370)
(e) Select a ring gear teeth side plate washer so that is no
clearance between the outer race and case.
(f) Remove the plate washers and differential case.
(g) Install the plate washer into the ring gear back side of the
carrier.

Z03861Plate WasherPlate Washer
F11755
Z03863
Plate
Washer
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA-53
2003 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(h) Place the other plate washer onto the differential case to-
gether with the outer race, and install the differential case
with the outer race into the carrier.
(i) Tap on the ring gear with a plastic hammer so that the
washers fit to the bearing.
(j) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0070 in.)
If the backlash is not within the specification, adjust by either in-
creasing or decreasing the thickness of washers on both sides
by an equal amount.
HINT:
There should be no clearance between the plate washer and
case.
Make sure that there is ring gear backlash.
10. ADJUST SIDE BEARING PRELOAD
(a) Remove the ring gear teeth side plate washer and mea-
sure the thickness.
(b) Using the backlash as a reference, install a new washer
of 0.06 - 0.09 mm (0.0024 - 0.0035 in.) thicker than the
washer removed.
HINT:
Select a washer which can be pressed in 2/3 of the way with
your finger.
(c) Using a plastic hammer, install the plate washer.
(d) Align matchmarks on the bearing cap and differential car-
rier.
(e) Tighten the 4 bolts.
Torque: 85 N´m (870 kgf´cm, 63 ft´lbf)
HINT:
Turn the ring gear several times to make the side bearings
smooth.

F11477
F11478
R02495
Proper ContactSelect an adjusting shim that will bring the drive
pinion closer to the gear.Heel Contact Face Contact
Toe Contact Flank Contact
Select an adjusting shim that will shift the drive
pinion gear away from the ring gear. SA-54
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
2004 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(f) Using a dial indicator, adjust the ring gear backlash until
it is within the specification.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0070 in.)
If the backlash is not within the specification, adjust by either in-
creasing or decreasing the thickness of washers on both sides
by an equal amount.
HINT:
The backlash will change by about 0.02 mm (0.0008 in.) corre-
sponding to 0.03 mm (0.0012 in.) change in the plate washer.
11. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus
0.4 - 0.6 N´m (4 - 6 kgf´cm, 3.5 - 5.2 in.´lbf)
12. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear
with red lead primer.
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.

FA2008
Washer
F05159
SST
F05964
SST
- SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA-55
2005 Author
: Date
:
2004 LAND CRUISER (RM1071U)
If the teeth are not contacting properly, use the following table
to select a proper washer for correction.
Washer thickness
Thickness mm (in.)Thickness mm (in.)
1.70 (0.0669)2.03 (0.0799)
1.73 (0.0681)2.06 (0.0811)
1.76 (0.0693)2.09 (0.0822)
1.79 (0.0704)2.12 (0.0835)
1.82 (0.0717)2.15 (0.0847)
1.85 (0.0729)2.18 (0.0858)
1.88 (0.0740)2.21 (0.0870)
1.91 (0.0752)2.24 (0.0882)
1.94 (0.0764)2.27 (0.0894)
1.97 (0.0776)2.30 (0.0906)
2.00 (0.0787)2.33 (0.0918)
13. REMOVE COMPANION FLANGE (See page SA-40)
14. REMOVE OIL SLINGER
15. REMOVE REAR BEARING (See page SA-40)
16. REMOVE REAR BEARING OUTER RACE
(See page SA-40)
17. INSTALL BEARING SPACER AND OIL STORAGE
RING
(a) Install a new bearing spacer.
(b) Using SST and a hammer, install a new oil storage ring.
SST 09316-6001 1 (09316-00011), 09506-35010
18. INSTALL REAR BEARING OUTER RACE
Using SST and a hammer, install the bearing outer race.
SST 09316-6001 1 (09316-00011), 09506-35010
19. INSTALL REAR BEARING AND OIL SLINGER
20. INSTALL OIL SEAL
(a) Coat the hypoid gear oil to a new oil seal periphery.