TOYOTA LAND CRUISER 1998 Factory Repair Manual

TR06Q-02
TF1039
Q00530
TF1033
TF1034
Q08384
- TRANSFERREAR EXTENSION HOUSING
TR-41
1929 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. REMOVE OIL PUMP DRIVE SHAFT
2. REMOVE OIL PUMP COVER
(a) Using a torx socket wrench (T30), remove the 3 screws.
(b) Install the 2 suitable bolts to the pump cover.
(c) Remove the pump cover from the rear extension housing.
3. REMOVE DRIVE ROTOR FROM DRIVEN ROTOR
4. REMOVE DRIVEN ROTOR FROM REAR EXTENSION
HOUSING
5. REMOVE SCREW PLUG, SPRING, BALL AND VALVE
SEAT
(a) Using a hexagon wrench, remove the screw plug.
(b) Using a magnetic finger, remove the spring, ball and valve
seat from the rear extension housing.

D04353
TF0959
SST
Q08385
Q08481
SST TR-42
- TRANSFERREAR EXTENSION HOUSING
1930 Author
: Date
:
2004 LAND CRUISER (RM1071U)
6. REMOVE OIL PUMP PLATE
Remove the 3 bolts and oil pump plate.
7. REMOVE SPEED SENSOR DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the speed sensor drive gear.
8. REMOVE REAR OUTPUT SHAFT
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a hammer, remove the rear output shaft.
SST 09325-12010
(c) Remove the 2 seal rings from the rear output shaft.
9. REMOVE DUST DEFLECTOR
(a) Using a screwdriver and hammer, remove the rear exten-
sion housing dust deflector.
(b) Using a screwdriver and hammer, remove the rear output
shaft dust deflector.
10. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal from the rear extension
housing.
11. REMOVE BALL BEARING
(a) Using a screwdriver, remove the snap ring.
(b) Using SST and a press, remove the ball bearing from the
rear extension housing.
SST 09316-6001 1 (09316-00011, 09316-00021)

TR06R-02
Q02615
Q02616
Q02617
- TRANSFERREAR EXTENSION HOUSING
TR-43
1931 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSPECTION
1. INSPECT DRIVEN ROTOR BODY CLEARANCE
(a) Install the drive rotor and driven rotor to the rear extension
housing.
(b) Using a feeler gauge, measure the body clearance be-
tween the drive rotor and extension housing.
Standard clearance:
0.08 - 0.17 mm (0.0031 - 0.0067 in.)
Maximum clearance:
0.17 mm (0.0067 in.)
If the body clearance exceeds the maximum, replace the drive
rotor and driven rotor.
2. INSPECT DRIVEN ROTOR TIP CLEARANCE
Using a feeler gauge, measure the tip clearance between the
drive rotor and driven rotor.
Standard clearance:
0.05 - 0.15 mm (0.0020 - 0.0059 in.)
Maximum clearance:
0.15 mm (0.0059 in.)
If the tip clearance exceeds the maximum, replace the drive ro-
tor and driven rotor.
3. INSPECT OIL PUMP SIDE CLEARANCE
Using a steel straight edge and feeler gauge, measure the side
clearance of oil pump.
Standard clearance:
0.03 - 0.10 mm (0.0012 - 0.0039 in.)
Maximum clearance:
0.10 mm (0.0039 in.)
If the side clearance exceeds the maximum, replace the drive
rotor and driven rotor.

TR06S-02
TF0964
SST
TF0962
Q08482
SST
TF0967
SST
Q08482
SST TR-44
- TRANSFERREAR EXTENSION HOUSING
1932 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL BALL BEARING
(a) Using SST and a press, install the ball bearing.
SST 09316-6001 1 (09316-00011, 09316-00031)
(b) Select a snap ring that will allow the minimum axial play.
MarkThickness mm (in.)
A1.70 (0.0669)
B1.80 (0.0709)
(c) Using a screwdriver, install a new snap ring.
2. INSTALL DUST DEFLECTOR
(a) Using SST and a hammer, install a new rear extension
housing dust deflector.
SST 09316-6001 1 (09316-00011, 09316-00041)
(b) Using SST and a press, install a new rear output shaft
dust deflector.
SST 09316-2001 1, 09316-60011 (09316-00011)
3. INSTALL OIL SEAL
(a) Apply MP grease to the lip of a new oil seal.
(b) Using SST and a hammer, drive in the oil seal.
SST 09316-6001 1 (09316-00011, 09316-00031)

TF0969
SST
TF0958
D04353
- TRANSFERREAR EXTENSION HOUSING
TR-45
1933 Author
: Date
:
2004 LAND CRUISER (RM1071U)
4. INSTALL REAR OUTPUT SHAFT
(a) Using SST and a press, install the rear output shaft.
SST 09316- 20011, 09316- 60011 (09316- 00011,
09316-00031)
(b) Install the 2 seal rings to the rear output shaft.
(c) Select a snap ring that will allow the minimum axial play.
MarkThickness mm (in.)
11.95 (0.0768)
22.05 (0.0807)
32.15 (0.0847)
42.25 (0.0886)
(d) Using a snap ring expander, install a new snap ring.
5. INSTALL SPEED SENSOR DRIVE GEAR
(a) Install the speed sensor drive gear.
(b) Using a snap ring expander, install the snap ring.
6. INSTALL OIL PUMP PLATE
(a) Install the oil pump plate.
(b) Install and torque the 3 bolts.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)

Q08384
TF0977
Q00529
TR-46
- TRANSFERREAR EXTENSION HOUSING
1934 Author
: Date
:
2004 LAND CRUISER (RM1071U)
7. INSTALL VALVE SEAT, BALL, SPRING AND SCREW
PLUG
(a) Apply gear oil to the ball.
(b) Install the valve seat, ball and spring.
(c) Apply liquid sealer to the screw plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Using a hexagon wrench, install and torque the screw
plug.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
8. INSTALL DRIVEN ROTOR
(a) Apply gear oil to the driven rotor.
(b) Install the driven rotor.
9. INSTALL DRIVE ROTOR
(a) Apply gear oil to the drive rotor.
(b) Install the drive rotor.
HINT:
Align the alignment marks.
10. INSTALL OIL PUMP COVER
(a) Install the oil pump cover.
(b) Using a torx socket wrench (T30), install and torque the
3 screws.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
NOTICE:
Align the oil hole of the rear extension housing and oil
groove end of the oil pump cover.
11. INSTALL OIL PUMP DRIVE SHAFT

TR069-02
D02653
 Gasket
Rear Extension
Housing
Vehicle Speed Sensor
Driven Gear
Oil Strainer
Case Cover Transfer Indicator Switch
(Neutral Switch)
Transfer Indicator Switch
(Low Switch)
37 (380, 27)
37 (380, 27)
37 (380, 27)
x9


37 (380, 27)

37 (380, 27)
x5 Adjusting Shim
Rear Case
Snap Ring Center Differential
Assemblyx8
Bearing Race
Shift Fork No. 1
Idler Gear Assembly Bearing Race
Shift Fork No. 1 Shaft
Bearing Race
Bearing Race
Input Shaft Assembly
Lever Lock Pin
Washer
 Oil Seal
Shift Inner Lever
Oil Receiver Motor ActuatorShift Outer Lever
11 (115, 8)
4.9 (50, 43 in.´lbf)

19 (190, 14)18 (185, 13)
12 (120, 9)
12 (120, 9)
37 (380, 27)
37 (380, 27)
x6 Transfer Indicator Switch
(Center Diff. Lock) Shift Fork No. 2 Shift Fork No. 2 ShaftOutput Gear
Snap Ring
Front Case
Breather Hose
Clutch Sleeve
Front Extension Housing Oil Seal
N´m (kgf´cm, ft´lbf)
: Specified torque
 Non-reusable part

Precoated partSpring
Ball Screw Plug
 Gasket
Slotted Spring Pin
Washer
- TRANSFERTRANSFER ASSEMBLY
TR-7
1895 Author
: Date
:
2004 LAND CRUISER (RM1071U)
TRANSFER ASSEMBLY
COMPONENTS

TR06X-02
D02690
D02862
Q07105
D02860
TR-8
- TRANSFERTRANSFER ASSEMBLY
1896 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. REMOVE BREATHER HOSE
2. REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR
Remove the bolt and driven gear.
3. REMOVE MOTOR ACTUATOR
Remove the 4 bolts and motor actuator.
4. REMOVE OUTPUT GEAR FROM FRONT CASE
5. REMOVE SCREW PLUG, SPRING AND BALL
(a) Using a torx socket wrench (T40), remove the screw plug.
(b) Using a magnetic finger, remove the spring and ball.
6. REMOVE TRANSFER INDICATOR SWITCH
Remove the 3 transfer indicator switches and 3 gaskets.
7. REMOVE FRONT EXTENSION HOUSING
Remove the 6 bolts and front extension housing.
HINT:
If necessary, tap the front extension housing lightly with a plas-
tic hammer.

Q00541
Front
Q02950
D02861
D02667
D02863
- TRANSFERTRANSFER ASSEMBLY
TR-9
1897 Author
: Date
:
2004 LAND CRUISER (RM1071U)
8. REMOVE CLUTCH SLEEVE WITH SHIFT FORK NO. 2
SHAFT AND SHIFT FORK NO. 2
9. SEPARATE SHIFT FORK NO. 2 SHAFT AND SHIFT
FORK NO. 2
(a) Using 2 screwdrivers and a hammer, tap out the 3 snap
rings from the shift fork No. 2 shaft.
(b) Separate the shift fork No. 2 shaft and shift fork No. 2.
10. REMOVE REAR EXTENSION HOUSING
Remove the 9 bolts and rear extension housing.
HINT:
If necessary, tap the rear extension housing lightly with a plastic
hammer.
11. REMOVE ADJUSTING SHIMS
12. REMOVE OIL STRAINER FROM REAR CASE
Remove the 2 bolts and oil strainer.
13. REMOVE CASE COVER
(a) Remove the 5 bolts.

D02668
D02669
D02864
TF0854
D02670
TR-10
- TRANSFERTRANSFER ASSEMBLY
1898 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(b) Using a brass bar and hammer, tap the case cover and
remove it.
14. SEPARATE FRONT CASE AND REAR CASE
(a) Using a snap ring expander, remove the snap ring from
the rear case.
(b) Remove the 8 bolts.
(c) Using a brass bar and hammer, tap the rear case and sep-
arate it.
15. REMOVE 2 BEARING RACES FROM REAR CASE
16. REMOVE INPUT SHAFT ASSEMBLY
Using a plastic hammer, remove the input shaft assembly from
the front case.