TOYOTA LAND CRUISER 1998 Factory Repair Manual

F05204
Matchmarks
F05205
F05206
SST
F05190
Matchmarks
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA-105
2055 Author
: Date
:
2004 LAND CRUISER (RM1071U)
15. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 ring gear set bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the differential case.
16. CHECK DIFFERENTIAL CASE RUNOUT
(a) Place the bearing outer races on their respective bear-
ings. Check that the right and left outer races are not inter-
changed.
(b) Install the differential case in the differential carrier.
(c) Tighten the adjusting nut just to where there is no play in
the bearing.
(d) Align the matchmarks on the bearing cap and differential
carrier.
(e) Install and uniformly tighten the 4 bearing cap bolts a little
at a time.
(f) Using a dial indicator, measure the differential case run-
out.
Maximum case runout: 0.04 mm (0.0016 in.)
(g) Remove the differential case.
17. REMOVE SIDE BEARINGS FROM DIFFERENTIAL
CASE
Using SST, remove the 2 side bearings from the differential
case.
SST 09950-00020, 09950-00030,
09950-4001 1 (09957-04010),
09950-60010 (09951-00480)
18. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the RH and LH differential cases.
(b) Remove the 8 bolts uniformly, a little at a time.
(c) Using a plastic hammer, separate the RH and LH differen-
tial cases.
(d) Remove the 2 side gear thrust washers, 2 side gears, spi-
der, 4 pinion gears and pinion gear thrust washers.

SA15R-1 1
SA-1 16
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2066 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-100).
HINT:
After installation, fill the differential with hypoid gear oil (See page SA-95), fill the brake reservoir with brake
fluid, bleed the brake system (See page BR-4), check for leaks and check the ABS speed sensor signal (See
page DI-505).

SA15Q-12
SA0510
F05191
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA-107
2057 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
(a) Install the 2 thrust washers to the side gears.
(b) Install the side gear to the differential case.
(c) Install the 4 pinion gears and thrust washers to the spider.
(d) Install the spider assembly to the differential case.
HINT:
Install the spider to the differential case tightly.
(e) Using a dial indicator, measure the side gear backlash
holding the side gear and spider.
Backlash: 0.02 - 0.15 mm (0.0008 - 0.0059 in.)
HINT:

Measure at all 4 locations.

Measure the backlash at the RH and LH differential
cases.
If the backlash is not within the specified value, install a thrust
washer of a different thickness.
Thrust washer thickness:
Thickness mm (in.)Thickness mm (in.)
1.55 (0.061)1.85 (0.073)
1.60 (0.063)1.90 (0.075)
1.65 (0.065)1.95 (0.077)
1.70 (0.067)2.00 (0.079)
1.75 (0.069)2.05 (0.081)
1.80 (0.071)2.10 (0.083)
2. ASSEMBLE DIFFERENTIAL CASE
(a) Reinstall the spider to the differential case.
HINT:
Install the spider to the differential case tightly.

F05190
Matchmarks
F05192
SST
F05193
SST
SST
SA1143
Boiling Water
F05204
Matchmarks
SA-108
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2058 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(b) Align the matchmarks and assemble the RH and LH dif-
ferential cases.
(c) Tighten the 8 bolts uniformly, a little at a time.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
3. INSTALL SIDE BEARINGS
(a) Using SST and a press, install the RH side bearing on the
differential case.
SST 09710-30050, 09950-70010 (09951-07100)
(b) Using SST and a press, install the LH side bearing on the
differential case.
SST 09710- 30050, 09950- 60010 (09951- 00480),
09950-70010 (09951-07100)
4. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the threads of the bolts and differential case with
the white gasoline.
(b) Clean the contact surfaces of the differential case and
ring gear.
(c) Heart the ring gear to about 100 °C (212 °F) in boiling wa-
ter.
(d) Carefully take the ring gear out of the boiling water.
(e) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(f) Align the matchmarks on the ring gear and differential
case.
(g) Temporarily install the 12 set bolts.
(h) After the ring gear cools down enough, torque the 12 set
bolts to which thread lock has been applied.
Thread lock:
Part No. 08833-00100, THREE BOND 1360 K
or equivalent
Torque: 137 N´m (1,400 kgf´cm, 101 ft´lbf)

F05194
F05804
SST Front: Rear:
SST
SA3102
SST
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA-109
2059 Author
: Date
:
2004 LAND CRUISER (RM1071U)
5. CHECK RING GEAR RUNOUT
(a) Place the bearing outer races on their respective bear-
ings. Check that the right and left outer races are not inter-
changed.
(b) Install the differential case onto the carrier and tighten the
adjusting nut just to where there is no play in the bearings.
(c) Using a dial indicator, check the ring gear runout.
Maximum runout: 0.05 mm (0.0020 in.)
(d) Remove the differential case.
6. INSTALL FRONT AND REAR BEARING OUTER
RACES
(a) Using SST and a press, install the front bearing outer
race.
SST 09950-60020 (09951-00710),
09950-70010 (09951-07150)
(b) Using SST and a press, install the rear bearing outer race.
SST 09950-60020 (09951-00890),
09950-70010 (09951-07150)
7. INSTALL DRIVE PINION REAR BEARING
(a) Install the plate 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.
(b) Using SST and a press, install the rear bearing onto the
drive pinion.
SST 09506-35010
8. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion and front bearing.
HINT:
Assemble the spacer and oil seal after adjusting the gear con-
tact pattern.
(b) Install the oil slinger.

R13414
SST
SA2450
SST
SA2446
F05195
SA-1 10
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2060 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Install the companion flange with SST.
SST 09950- 30012 (09951- 03010, 09953- 03010,
09954-03010, 09955-03030, 09956-03040)
(d) Using SST to hold the flange and adjust the drive pinion
preload by tightening the companion flange nut.
SST 09330-00021
NOTICE:

Coat the nut and screw 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
1.3 - 1.8 N´m (13 - 19 kgf´cm, 11.5 - 15.9 in.´lbf)
Reused bearing
0.64 - 0.92 N´m (6.5 - 9.4 kgf´cm, 5.7 - 8.1 in.´lbf)
HINT:
Measure the total preload after turning the bearing clockwise
and counterclockwise several times to make the bearing
smooth.
9. INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the 2 bearing outer races on their respective bear-
ings. Make sure that the right and left outer races are not
interchanged.
(b) Install the differential case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
10. INSTALL ADJUSTING NUTS
Install the 2 adjusting nuts on the carrier, making sure the nuts
are engaged properly.

F05196
Matchmarks
F05197
Z06953SST
F05198SST
SA2444
SST
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA-1 11
2061 Author
: Date
:
2004 LAND CRUISER (RM1071U)
11. INSTALL BEARING CAPS
Align the matchmarks on the bearing 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 engaged properly. Reinstall the adjusting nuts if
necessary.
12. ADJUST SIDE BEARING PRELOAD
(a) Torque the 4 bolts.
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)
(b) Then loosen them to the point where the adjusting nuts
can be turned by SST.
SST 09504-0001 1
(c) Tighten the 4 bolts.
Torque: 9.8 N´m (100 kgf´cm, 7 ft´lbf)
(d) Using SST, torque the adjusting nut on the ring gear side
until the ring gear has a backlash of about 0.2 mm (0.008
in.).
(e) While turning the ring gear, use the SST to fully tighten the
adjusting nut on the drive pinion side. After the bearings
are settled, loosen the adjusting nut on the drive pinion
side.
(f) Place a dial indicator on the top of the adjusting nut on the
ring gear side.
(g) Adjust the side bearing to zero preload by tightening the
other adjusting nut until the pointer on the indicator be-
gins to move.

F05198SST
Z06918
SST
F05197
SA2446
F05199
SA-1 12
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2062 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(h) Using the SST, torque the adjusting nut 1 - 1.5 notches
from the zero preload position.
(i) Using a dial indicator, adjust the ring gear backlash until
it is within the specified value.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
HINT:
The backlash is adjusted by turning the right and left adjusting
nuts by equal amount. For example, loosen the nut on the left
side 1 notch and torque the nut on the right side 1 notch.
(j) Torque the 4 bearing cap bolts.
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)
(k) After rotating the ring gear 5 turns or more, recheck the
ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
13. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the preload with the teeth of
the drive pinion and ring gear in contact.
Preload (at starting):
Drive pinion preload plus
0.38 - 0.63 N´m (3.9 - 6.5 kgf´cm, 3.3 - 5.6 in.´lbf)
14. 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) Turn the companion flange, in both directions to inspect
the ring gear for proper tooth contact.

FA2013
Proper ContactHeel Contact
Face Contact
Select an adjusting washer that will bring the drive
pinion closer to the ring gear.
Toe Contact Flank Contact
Select an adjusting washer that will shift the drive pinion
away from the ring gear.
FA2041
Plate Washer
F05116
SST
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA-1 13
2063 Author
: Date
:
2004 LAND CRUISER (RM1071U)
If the teeth are not contacting properly, use the following table
to select a proper washer for correction.
Plate washer thickness:
Thickness mm (in.)Thickness mm (in.)
1.050 (0.04134)1.325 (0.05217)
1.075 (0.04232)1.350 (0.05315)
1.100 (0.04331)1.375 (0.05413)
1.125 (0.04429)1.400 (0.05512)
1.150 (0.04528)1.425 (0.05610)
1.175 (0.04626)1.450 (0.05709)
1.200 (0.04724)1.475 (0.05807)
1.225 (0.04823)1.500 (0.05906)
1.250 (0.04921)1.525 (0.06004)
1.275 (0.05020)1.550 (0.06102)
1.300 (0.05118)-
15. REMOVE COMPANION FLANGE (See page SA-102)
16. REMOVE OIL SLINGER AND FRONT BEARING (See
page SA-102)
17. REMOVE BEARING OUTER RACE
Using SST, remove the bearing outer race.
SST 09308-00010
18. INSTALL NEW BEARING SPACER

Z06903
SST
SA2454
SST
R13414
SST
SA2351
SST
SA2446
SA-1 14
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
2064 Author
: Date
:
2004 LAND CRUISER (RM1071U)
19. INSTALL BEARING OUTER RACE
Using SST and a hammer, install the bearing outer race.
SST 09316-6001 1 (09316-00011, 09316-00021)
20. INSTALL FRONT BEARING AND OIL SLINGER
21. INSTALL OIL SEAL
(a) Coat the hypoid gear oil to a new oil seal periphery.
(b) Using SST and a hammer, install the oil seal.
SST 09214-7601 1
Oil seal drive in depth: 0.5 mm (0.020 in.)
(c) Coat MP grease to the oil seal lip.
22. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange.
SST 09950- 30012 (09951- 03010, 09953- 03010,
09954-03010, 09955-03030, 09956-03040)
(b) Coat the threads of a new nut with gear oil.
(c) Using SST to hold the flange, install the nut.
SST 09330-00021
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
23. ADJUST DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash
between the drive pinion and ring gear.
Preload (at starting):
New bearing
1.3 - 1.8 N´m (13 - 19 kgf´cm, 11.5 - 15.9 in.´lbf)
Reused bearing
0.64 - 0.92 N´m (6.5 - 9.4 kgf´cm, 5.7 - 18.1 in.´lbf)
If the preload is greater than the specified value, replace the
bearing spacer.