TOYOTA LAND CRUISER 1998 Factory Repair Manual

F05185
SA2475
Matchmarks
F05443SST
SST
F05187
SST
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
SA-125
2075 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(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.
20. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the case and cover.
(b) Using a torx socket (E10), remove the 5 set bolts and 3
pinion shaft pins.
(c) Separate the cover and case.
(d) Remove the 2 side gears, side gear thrust washers, 4 pin-
ion gears, pinion gear thrust washers, 3 pinion shafts and
holder from the differential case.
21. REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
Using SST, remove the side bearing.
SST 09950- 40011 (09951- 04010, 09952- 04010,
09953- 04020, 09955- 04061, 09957- 04010,
09958-0401 1), 09950-60010 (09951-00580)
HINT:
Fix the claws of SST to the notches in the differential case.
22. REMOVE SIDE BEARING FROM DIFFERENTIAL COV-
ER
Using SST, 4 bolts and a press, remove the side bearing.
SST 09950-60010 (09951-00580),
09950-70010 (09951-07100)

SA15X-09
SA-138
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
2088 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-100).
AFTER INSTALLATION, FILL DIFFERENTIAL WITH HYPOID GEAR OIL (See page SA-95)
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).

SA15W-1 1
SA0510
R08274
R08276
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
SA-127
2077 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 2 side gears.
(b) Install the 4 thrust washers to the 4 pinion gears.
(c) Install the side gear into the case.
(d) Install the holder into the case.
(e) Install the 4 pinion gears with the thrust washers.
(f) Align the holes of the differential case and pinion shaft,
and install the 3 pinion shafts.
(g) Install the side gear to the cover.
(h) Align the matchmarks and install the case and cover.
(i) Using a torx socket (E10), install the 5 bolts and 3 pinion
shaft pins.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
(j) Using a dial indicator, while holding the side gear, mea-
sure the backlash.
Backlash: 0.02 - 0.15 mm (0.0008 - 0.0059 in.)
If the backlash is not within the specified value, install the thrust
washer of a different thickness.
HINT:

Try to select washers of the same size for both sides.

Measure at all 4 locations.
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)
(k) After measuring backlash, remove the 5 set bolts and 3
pinion shaft pins.

R13246MatchmarksAdhesive
F05178
SST
F05179
SST
SA1143
Boiling Water SA-128
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
2078 Author
: Date
:
2004 LAND CRUISER (RM1071U)
2. ASSEMBLE DIFFERENTIAL CASE
(a) Clean the threads of the bolts, pinion shaft pins, case and
cover with the white gasoline.
(b) Coat the threads of the bolts and pinion shaft with adhe-
sive.
Adhesive:
Part No. 08833-00070, THREE BOND 1324
or equivalent
(c) Align the matchmarks, install the case and cover.
(d) Using a torx socket (E10), install the 5 bolts and 3 pinion
shaft pins.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
3. INSTALL SIDE BEARINGS
(a) Cover side:
Using SST and a press, install the side bearing on the dif-
ferential cover.
SST 09550-60010
(b) Ring gear side:
Using SST and a press, install the side bearing on the dif-
ferential case.
SST 09550-60010
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) Heat 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 on the differential case.
(f) Align the matchmarks on the ring gear and differential
case.

F05188
F05182
F05804
SST
SST Front: Rear:
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
SA-129
2079 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(g) Temporarily install the 12 set bolts.
(h) After the ring gear has cooled down enough, torque the
12 set bolts to which thread lock has been applied.
Thread lock:
Part No.08833-00100, THREE BOND 1360K
or equivalent
Torque: 137 N´m (1,400 kgf´cm, 101 ft´lbf)
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 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, check the ring gear runout.
Maximum runout: 0.05 mm (0.0020 in.)
(g) Remove the differential case.
6. INSTALL DRIVE PINION FRONT AND REAR BEARING
OUTER RACES
(a) Using SST and a press, install the front bearing outer
race.
SST 09950-60020 (09951-00710),
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)

SA3102
SST
R13414
SST
SA2450
SST
SA2446
SA-130
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
2080 Author
: Date
:
2004 LAND CRUISER (RM1071U)
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.
(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.

R08261
R08262
R08263
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
SA-131
2081 Author
: Date
:
2004 LAND CRUISER (RM1071U)
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 races are not inter-
changed.
(b) Install the assembled plate washer onto the side bearing.
(c) Install the differential case in the carrier.
(d) Settle down the plate washer and bearing snugly by tap-
ping 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.
10. ADJUST RING GEAR BACKLASH
(a) Using a dial indicator, while holding the side bearing of the
ring gear side measure the backlash.
Backlash (Reference): 0.15 mm (0.0059 in.)
(b) Select a cover side plate washer using the backlash as a
reference.
Plate washer thickness:
MarkThickness mm (in.)MarkThickness mm (in.)
12.67 (0.1051)133.03 (0.1193)
22.70 (0.1063)143.06 (0.1205)
32.73 (0.1075)153.09 (0.1217)
42.76 (0.1087)163.12 (0.1228)
52.79 (0.1098)173.15 (0.1240)
62.82 (0.1110)183.18 (0.1252)
72.85 (0.1122)193.21 (0.1264)
82.88 (0.1134)203.24 (0.1276)
92.91 (0.1146)213.27 (0.1287)
102.94 (0.1157)223.30 (0.1299)
112.97 (0.1169)233.33 (0.1311)
123.00 (0.1181)--

R08264
R08265
R08263
RA0090
SA-132
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
2082 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Select a ring gear side plate washer so that there is no
clearance between the outer race and case.
(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 differential case together
with the outer races, and install the differential case with
the outer race into the carrier.
(g) Settle down the plate washer and bearing snugly by tap-
ping on the ring gear with a plastic hammer.
(h) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
If it is not within the specified value, adjust it by either increasing
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.
Ensure that there is ring gear backlash.
11. ADJUST SIDE BEARING PRELOAD
(a) After adjustment using the backlash as reference, re-
move the ring gear side plate washer.
(b) Using a micrometer, measure the thickness of the re-
moved plate washer.
(c) Install a new washer 0.06 - 0.09 mm (0.0024 - 0.0035 in.)
thicker than the removed washer.
HINT:
Select a washer which can be pressed in 2/3 of the way with fin-
ger.

R08269
SST
F05183
SA2446
F05170
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
SA-133
2083 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(d) Using SST, tap in the plate washer.
SST 09504-22012
(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, measure the ring gear backlash un-
til it is within the specified value.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
If the backlash is not within the specified value, adjust by either
increasing or decreasing the thickness of washers on both
sides by an equal amount.
(h) After rotating the ring gear 5 turns or more, recheck the
ring gear backlash.
12. 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
0.3 - 0.5 N´m (3 - 5 kgf´cm, 2.7 - 4.4 in.´lbf)
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR
(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 ContactFace Contact
Select an adjusting washer that will bring the drive
pinion closer to the ring gear.
Toe ContactFlank Contact
Select an adjusting washer that will shift the drive pinion
away from the ring gear.
FA2041
Plate Washer
F05116
SST
SA-134
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ Diff. Lock)
2084 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)-
14. REMOVE COMPANION FLANGE (See page SA-121)
15. REMOVE OIL SLINGER AND FRONT BEARING (See
page SA-121)
16. REMOVE BEARING OUTER RACE
Using SST, remove the bearing outer race.
SST 09308-00010
17. INSTALL NEW BEARING SPACER