Indicator TOYOTA LAND CRUISER 1996 J80 Owners Manual

Z06918
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−95
1996 LAND CRUISER (RM451U)
(g) Using the SST, torque the adjusting nut 1−1.5 notches
from the zero preload position.
(h) 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.)
HINT:
The backlash is adjusted by turning the left and right adjusting
nuts equal amounts. For example, loosen the nut on the left
side one notch and torque the nut on the right side one notch.
(i) Torque the 4 bearing cap bolts. Torque:78 N·m (800 kgf·cm, 58 ft·lbf)
(j) Recheck the ring gear backlash. Backlash: 0.15 − 0.20 mm (0.0059−0.0079 in.)
17. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus
w/o Differential lock
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
w/ Differential lock
0.3− 0.7 N·m (3 − 7 kgf·cm, 2.6 − 6.1 in.·lbf)
18. 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.
(b) Turn the companion flange, pin both directions to inspect the ring gear for proper tooth contact.
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Z15220
FIPG Width Approx.
1 − 2 mm (0.04 − 0.08 in.)
SA2129
Z10150
Adhesive
SA−98
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
25. RECHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Ring gear backlash:
0.15 − 0.20 mm (0.0059 − 0.0079 in.)
26. RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
27. CHECK RUNOUT OF COMPANION FLANGE (See
page SA−80 )
28. w/o DIFFERENTIAL LOCK: INSTALL ADJUSTING NUT LOCKS
(a) Install 2 new nut locks on the bearing caps.
(b) Tightening 2 bolts, bend the nut locks. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
29. w/ DIFFERENTIAL LOCK: INSTALL ACTUATOR, SHIFT FORK AND SLEEVE
(a) Clean contacting surfaces of any FIPG material using gasoline or alcohol.
(b) Apply FIPG to the actuator.
FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
HINT:
Install the actuator within 10 minutes after applying FIPG.
(c) Install the actuator to the differential and match the shift fork hole.
(d) Clean the threads of set bolt and fork shaft with the white
gasoline.
(e) Coat the threads of the set bolt with adhesive.
Adhesive: Part No. 08833 −00070, THREE BOND 1324
or equivalent
(f) Tighten the shift fork shaft set bolt. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
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SA2133
SA2131
Z15219
FIPG Width Approx.
1 − 2 mm (0.04 − 0.08 in.)
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−99
1996 LAND CRUISER (RM451U)
(g) Engage the sleeve with the dog clutch of the differential
case.
(h) Tighten the 4 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
30. w/ DIFFERENTIAL LOCK: INSTALL COVER
(a) Clean contacting surfaces of any FIPG material using gasoline or alcohol.
(b) Apply FIPG to the cover.
FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
HINT:
Install the cover within 10 minutes after applying FIPG.
(c) Tighten the 3 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
31. w/ DIFFERENTIAL LOCK: INSTALL INDICATOR SWITCH
Install the indicator switch with a new gasket.
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
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SA1VL−03
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
SA−101
958
Author: Date:
1996 LAND CRUISER (RM451U)
DIFFERENTIAL LOCKING SYSTEM
ON−VEHICLE INSPECTION
1. INSPECT DIFFERENTIAL LOCK SYSTEM
(a) Inspect the indicator lights.
Check that the indicator lights (front side and rear side)
light up for approx. 1 second when the ignition switch is
turned ON.
(b) Inspect the differential lock operation. (1) Jack up the vehicle then start the engine.
(2) Put the transfer shift lever on the L position.
(3) When the Diff. lock control switch is set to the RR
position, the indicator light (rear side) is turned on.
Differential lock is applied to the rear wheel at this
time.
HINT:
If the gears of the differential lock system are not meshed, the
indicator light remains blinking, so rotate the tires to mesh the
gear.
(4) When the Diff. lock control switch is at the OFF posi-
tion, the indicator light goes off.
Differential lock is released for the rear wheel at this
time.
(5) When the Diff. lock control switch is set to the FR/ RR position, the indicator lights (front side and rear
side) are turned on.
Differential lock is applied to both the front wheels
and rear wheels at this time.
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Z07254
M3 M4 M1 M2
Z07255
Wire Harness Side
SA−102
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
959
Author: Date:
1996 LAND CRUISER (RM451U)
(6) Check the voltage between the terminals of the Diff.
lock ECU when switching the Diff. lock control
switch with the speedometer, registering approx. 8
km/h (5 mph) or more.
(7) Check that the indicator lights blink when center Diff. lock release mode is set.
Diff. lock is released for both the front wheels and
rear wheels at this time.
(8) Return the Diff. lock control switch to OFF.
(9) Stop the engine and lower the vehicle.
2. INSPECT DIFF. LOCK SYSTEM CIRCUIT
(a) Inspect the system circuit with connector disconnected. Disconnect the connector from the Diff. lock ECU and in-
spect the connector on the wire harness side, as shown
in the chart.
Trouble Part/
Terminals (Symbols)ConditionSpecified V alue
Rear diff. lock actuator/
1 (M2) − 3 (M1)−Less than 100 Ω
Front diff. lock actuator/
5 (M4) − 7 (M1)−Less than 100 Ω
Body ground/
13 (GND) − Body ground−Continuity
Vehicle speed sensor/
4(SPD) − Body groundVehicle moving slowly1 pulse each 40 cm (15.75 in.)
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Z07256
ECU Side
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
SA−103
960
Author: Date:
1996 LAND CRUISER (RM451U) DIFF. fuse/
8 (IG) − Body ground
Ignition switch ONBattery positive voltage
Rear diff. lock position switch/
2 (RLP) − Body groundIgnition switch ON,
Indicator light (Rear) ONAbout 0 V
Ignition switch ON,
Indicator light (Rear) OFFBattery positive voltage
Front diff. lock position switch/ 9 (FLP) − Body ground
Ignition switch ON,
Indicator light (front) ON.About 0 V
Ignition switch ON,
Indicator light (front) OFFBattery positive voltage
Center diff. indicator switch/ 15 (4WD) − Body groud
Ignition switch ON,
Indicator light (Center diff. lock) ONAbout 0 V
Ignition switch ON,
Indicator light (Ce nter diff. lock) OFFBattery positive voltage
Differential lock control switch/
12 (R) − Body ground
Ignition switch ON,
Diff. lock control switch RR or FR RRBattery positive voltage
Ignition switch ON,
Diff. lock control switch OFFAbout 0 V
Differential lock control switch/ 6 (RF) − Body ground
Ignition switch ON,
Diff. lock control switch FR RRBattery positive voltage
Ignition switch ON,
Diff. lock control switch OFF or RRAbout 0 V
HINT:
When a signal enters the ECU to LOCK the front dif ferential and
set the rear differential to FREE (when battery positive voltage
is inputted to terminal 6 (RF) of ECU and about 0 V is inputted
to terminal 12 (R)), or a signal to FREE both the front and rear
differentials, the indicator lights keep blinking until the ignition
switch is turned off (Fail−safe function).
If the circuit is not as specified, check and repair or replace the
trouble part shown in the table above.
(b) Inspect the battery positive voltage Battery positive voltage: 10 − 14.5 V
(c) Inspect the system circuit with connector connected (1) Turn the ignition switch to the ON position.
(2) Keep the center Diff. lock condition.
(3) Remove the Diff. lock ECU.
(4) Using a voltmeter, measure the voltage when thedifferential lock control switch is in the position, as
shown below.
Terminals (Symbols)Switch PositionSTD Voltage (V)
15 (4WD) − 13 (GND)−0.5 or less
9 (FLP) − 13 (GND)FR RR0.5 or less
2 (RLP) − 13 (GND)RR or FR RR0.5 or less
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SA1948
21
4
Z07264
Ohmmeter
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
SA−105
962
Author: Date:
1996 LAND CRUISER (RM451U)
4. INSPECT DIFF. LOCK CONTROL SWITCH
Inspect the switch continuity between terminals, as shown.
Switch PositionTerminalsSpecified Condition
OFF1 − 2No continuity
1 − 4No continuity
RR1 − 2No continuity
1 − 4Continuity
FR RR1 − 2Continuity
1 − 4Continuity
If continuity is not as specified, replace the switch.
5. INSPECT DIFF. LOCK POSITION SWITCH
(a) Front and Rear:
Inspect the diff. lock position switch.
(1) Check that there is continuity between terminalswhen the switch is pushed (differential connected
position).
(2) Check that there is no continuity when the switch is
free (differential disconnected position).
If operation is not as specified, replace the switch.
(b) Inspect the center diff. indicator switch.
6. INSPECT VEHICLE SPEED SENSOR AND INDICATOR
LIGHT
(a) Inspect the vehicle speed sensor (See page BE−34).
(b) Inspect the indicator light.
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SR16O−01
Z14503
Dial Indicator30 mm
(1.18 in.)
Z14504
Dial Indicator
Z10600
Z06211
SR−38
−
STEERING POWER STEERING GEAR
1996 LAND CRUISER (RM451U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT BALL CLEARANCE
Using a dial indicator, check the ball clearance. Move the worm
gear up and down. Maximum clearance: 0.15 mm (0.0059 in.)
2. INSPECT CROSS SHAFT ADJUSTING SCREW THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance. Standard clearance: 0.03 − 0.05 (0.0012 − 0.0020 in.)
3. IF NECESSARY, ADJUST CROSS SHAFT ADJUSTING SCREW THRUST CLEARANCE
(a) Using a chisel and hammer, unstake the No.1 lock nut.
(b) Using SST, remove the No.1 lock nut. SST 09630−00014 (09631 −00051)
(c) Using a screwdriver, adjust the adjusting screw for correct thrust clearance.
(d) Using the SST, tighten a new lock nut.
(e) Using a chisel and hammer, stake the lock nut.
4. IF NECESSARY, REPLACE OIL SEAL, METAL SPACER AND TEFLON RING
(a) Using a screwdriver, pry out the oil seal from the gear
housing.
(b) Using snap ring pliers, remove the snap ring from the gear
housing.
(c) Remove the metal spacer, teflon ring and O −ring from the
gear housing.
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SS1E9−02
−
SERVICE SPECIFICATIONS TRANSFER
SS−27
1996 LAND CRUISER (RM451U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Oil pump plate and separator x Rear extension housing4.95043 in.·lbf
Oil pump cover x Rear extension housing4.95043 in.·lbf
Lever lock pin121209
Oil strainer x Rear case4.95043 in.·lbf
Oil receiver x Front case121209
Case cover x Rear case3738027
Rear extension housing x Rear case3738027
Front extension housing x Front case3738027
Center differential lock Indicator switch3738014
L4 position switch3738027
Neutral position switch3738027
Screw plug x Front case1919014
Screw plug x Rear extension housing2930022
Motor actuator x Front case1818513
Differential front case x Differential rear case
Temporarily tighten98
881,00090072
65
Front case x Rear case3738027
Rear case x Retainer3940028
Dynamic damper x Rear extension housing3738027
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SS1ED−02
−
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
SS−33
1996 LAND CRUISER (RM451U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
FRONT
Axle hub x Disc6465047
Axle hub bearing lock nut6465047
Flange x Axle hub3536026
Brake caliper x Axle carrier1231,25090
Brake caliper x Flexible hose3031022
Steering knuckle x Knuckle arm9698071
Bearing cap x Steering knuckle9698071
Knuckle arm x Tie rod9192567
Steering knuckle x Knuckle spindle4747534
Oil seal end retainer x Knuckle arm5.45548 in.·lbf
ABS speed sensor set bolt x Steering knuckle1818513
Hub nut Steel wheel
Aluminum wheel147
1031,500
1,050109 76
Drain plug4950036
Filler plug4950036
Propeller shaft x Companion flange8890065
Side bearing cap x Differential carrier7880058
Ring gear x Differential case9798571
Drive pinion x Companion flange196 − 3432,000 − 3,500145 − 253
Differential LH case x RH case4748035
Differential lock shift retainer2424017
Differential lock screw plug2222016
Differential lock indicator switch4041030
Differential lock actuator2627020
Differential carrier x Axle housing2728020
Adjusting nut lock x Bearing cap131309
Follow spring x Frame9.29482 in.·lbf
Stabilizer bar x Axle housing2526019
Shock absorber x Axle housing6970051
Shock absorber x Frame6970051
Stabilizer bar link x Cover1818513
Stabilizer bar link x Link bracket1031,05076
Lateral control rod x Frame1711,750127
Lateral control rod x Axle housing1711,750127
Leading arm x Frame1771,800130
Leading arm x Axle housing1711,750127
REAR
Rear axle shaft x Axle hub3434025
Rear axle bearing lock nut5960043
Rear axle bearing lock nut screw5.45548 in.·lbf
Brke caliper x Axle carrier1031,05076
ABS speed sensor set bolt1818513
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