TOYOTA LAND CRUISER 1996 J80 Workshop Manual

RS0PK−01
R13515
Front Passenger Airbag Assembly
Steering Wheel Pad Airbag Sensor Assembly
−
SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR
RS−37
1136
Author: Date:
1996 LAND CRUISER (RM451U)
WIRE HARNESS AND CONNECTOR
LOCATION
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

RS0PJ−01
RS−38
−
SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR
1996 LAND CRUISER (RM451U)
INSPECTION
HINT:
The SRS wire harness is integrated with the cowl wire harness assembly and \
floor wire harness assembly.
The wires for the SRS wire harness are encased in a black corrugated tube a\
nd all the connectors in the
system are a standard yellow color.
1. VEHICLES NOT INVOLVED IN COLLISION
Do a diagnostic system check (See page DI−240).
2. VEHICLES INVOLVED IN COLLISION
(a) Do a diagnostic system check (See page DI−240).
(b) Check for breaks in all wires of the SRS wire harness, and for exposed c\
onductors.
(c) Check to see if the SRS wire harness connectors are cracked or chipped.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

RS0PI−01
−
SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR
RS−39
1996 LAND CRUISER (RM451U)
REPLACEMENT
In the following cases, replace the wire harness or connector.
If any part of the SRS wire harness or any connector has been found to be \
faulty in troubleshoot-
ing.
If any part of the SRS wire harness or any connector has been found to be \
faulty during the check
in items 2−(b) or (c).
NOTICE:
If the wire harness used in the SRS is damaged, replace the whole wire h\
arness assembly.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA1U7−01
−
SUSPENSION AND AXLE TROUBLESHOOTING
SA−1
858
Author: Date:
1996 LAND CRUISER (RM451U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
(w/ Differential locking system):
Check that center differential lock mode is set.
When switching differential Free↔Lock, the indicator lamp will blink if the gears of the differen-
tial lock sleeve are not meshed. If this occurs, when the tires are rotated \
to apply differential
power to the differential, the differential locks and the indicator lamp\
light up.
SymptomSuspect AreaSee page
Wander/ pulls
1. Tires: worn or improperly inflated
2. Wheel alignmemt: incorrect
3. Steering linkage: loosen or worn
4. Hub bearings: loosen or worn
5. Steering gear: out of adjustment or brokenSA−3
SA−4
SR−47 SA−8
SR−41
Bottoming
1. Vehicle: overloaded
2. Spring weak
3. Shock absorber: worn out−
SA−49
SA−49
Sways/ pitches
1. Tires: worn or improperly inflated
2. Stabilizer bar: bent or broken
3. Shock absorber: worn outSA−3
SA−60
SA−49
Front wheel shimmy
1. Tires: worn or improperly inflated
2. Wheels: out of balance
3. Shock absorber: worn out
4. Wheel alignmemt: incorrect
5. Hub bearings: loosen or worn
6. Steering linkage: loosen or worn
7. Steering gear: out of adjustment or brokenSA−3
SA−3
SA−49 SA−3
SA−7
SR−45
SR−38
Abnormal tire wear
1. Tires: worn or improperly inflated
2. Wheel alignmemt: incorrect
3. Suspension parts: worn out
4. Shock absorber: worn outSA−3
SA−3 −
SA−49
Noise in front dif ferential
1. Oil level: low or wrong grade
2. Excessive backlash between pinion and ring gear
3. Ring, pinion ro side gears: worn or chipped
4. Pinion shaft bearing: worn
5. Side bearing: worn
6. Differential bearing: loosen or wornSA−21
SA−29
SA−29
SA−29
SA−29
SA−29
Oil leak from front dif ferential
1. Oil level: too high or wrong grade
2. Drive pinion oil seal: worn or damaged
3. Side gear oil seal: worn or damaged
4. Companion flange: loosen or damaged
5. Side gear shaft: damagedSA−21
SA−29
SA−29
SA−29
SA−29
Noise in rear axle
1. Oil level: low or wrong grade
2. Excessive backlash between pinion and ring gear
3. Ring, pinion ro side gears: worn or chipped
4. Pinion shaft bearing: worn
5. Axle shaft bearing: worn
6. Differential bearing: loosen or wornSA−73
SA−87
SA−87
SA−87
SA−87
SA−87
Oil leak from rear axle1. Oil seal: worn or damaged
2. Rear axle housing: crackedSA−73
−
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA−2
−
SUSPENSION AND AXLE TROUBLESHOOTING
859
Author: Date:
1996 LAND CRUISER (RM451U)
Oil leak from rear dif
ferential
1. Oil level: too high or wrong grade
2. Oil seal: worn or damaged
3. Companion flange: loosen or damagedSA−73
SA−73
SA−87
Indicator lights do not light up
1. Fusible link: blown
2. GAUGE fuse: blown
3. Bulb: burned out
4. Wiring or ground: faultyBE−9
BE−9
BE−32 −
Indicator lights do not light up
(Diff. lock control switch RR or FR RR position)
1. DIFF fuse: blown
2. Diff. lock control switch: faulty
3. Diff. lock ECU: faulty
4. Wiring or ground: faultyBE−9
SA−101
SA−101 −
Differential lock does not operate
1. Diff. lock position switch: faulty
2. Diff. lock actuator: faulty
3. Diff. lock ECU: faulty
4. Differential carrier (Diff. lock): faulty
5. Wiring or ground: faultySA−101
SA−101
SA−101
SA−101−
After differential lock, lock not release
When vehicle speed is higher than approx. 8 km/h (5mph)1. Speed sensor: faulty
2. Diff. lock ECU: faulty
3. Wiring or ground: faultyBE−32
SA−101 −
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA1U8−02
R03031
R13503
R07928
−
SUSPENSION AND AXLE TIRE AND WHEEL
SA−3
860
Author: Date:
1996 LAND CRUISER (RM451U)
TIRE AND WHEEL
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and for the proper inflation pres-
sure.
Cold tire inflation pressure: See page SS−30
(b) Check the tire runout. Tire runout: 3.0 mm (0.118 in.) or less
2. ROTATE TIRES
HINT:
See the illustration for where to rotate each tire.
3. INSPECT WHEEL BALANCE
(a) Check and adjust the Off−the−car balance.
(b) If necessary, check and adjust the On −the−car balance.
Unbalance after adjustment: 13.0 g (0.029 lb) or less
4. CHECK WHEEL BEARING LOOSENESS
Check the no backlash in the bearing shaft direction.
5. CHECK FRONT SUSPENSION FOR LOOSENESS
6. CHECK STEERING LINKAGE FOR LOOSENESS
7. CHECK BALL JOINT FOR LOOSENESS
8. CHECK SHOCK ABSORBER WORKS PROPERLY
Check for oil leaks
Check mounting bushings for wear
Bounce front and rear of the vehicle
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA1U9−02
Z03382
SA3213
AB
D
C
Front
R05628
A
B
A = B
SA−4
−
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT
861
Author: Date:
1996 LAND CRUISER (RM451U)
FRONT WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT
Clearance:
A (Follow spring clearance): 36 mm (1.42 in.)
B (Bumper stopper clearance): 104 mm (4.09 in.)
If the clearance of the vehicle is not standard, try to level the ve-
hicle by rocking it down.
If still not correct, check for bad springs or suspension parts.
2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR ONTO WHEEL ALIGNMENT TESTER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION
Camber
Left−right error1°00’ ± 45
45’ or less
Caster Left−right error3°00’ ± 1°
45’ or less
Steering axis inclination13 °00’ ± 45’
Camber, caster and steering axis inclination are not adjustable.
If measurements are not within the specification, inspect the
suspension parts for damaged and/or worn out parts and re-
place them as necessary.
4. INSPECT TOE −IN
To e−in
(total)A+B: 0.2 ° ± 0.2°
C −D: 2 ± 2 mm (0.08 ± 0.08 in.)
If toe− in is not within the specification, adjust by the tie rod end.
5. ADJUST TOE−IN
(a) Loosen the clamp bolts and nuts.
(b) Adjust toe−in to the correct value by turning the tie rod.
HINT:
Make sure that the lengths of the left and right tie rod ends are
the same.
(c) Torque the clamp bolts and nuts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

R05626
Front
Side+10
° +60
°
−10 °
FA0507
FA0018
A B
Front BA
A: Inside
B: Outside
−
SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT
SA−5
862
Author: Date:
1996 LAND CRUISER (RM451U)
HINT:
The clamps opening must be positioned at the rear of the tie rod
end face within 60 °±10° from the vehicle axis.
6. INSPECT WHEEL ANGLE
(a) Remove the caps of the knuckle stopper bolts and check the steering angles.
(b) Turn the steering wheel fully, and measure the turning angle.
Inside wheel32°00’ − 35°00’
Outside wheel31 °00’ (Reference)
HINT:
When the steering wheel is fully turned, make sure that the
wheel is not touching the body or brake flexible hose.
If maximum steering angles differ from the standard value, ad-
just the wheel angle with the knuckle stopper bolts.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
If the wheel angle still cannot be adjusted within limits, inspect
and replace damaged or worn steering parts.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA1UA−01
SA−6
−
SUSPENSION AND AXLE FRONT AXLE HUB
863
Author: Date:
1996 LAND CRUISER (RM451U)
FRONT AXLE HUB
COMPONENTS
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA1UB−01
SA2635
SST
−
SUSPENSION AND AXLE FRONT AXLE HUB
SA−7
1996 LAND CRUISER (RM451U)
REMOVAL
1. REMOVE FRONT WHEEL
2. REMOVE BRAKE CALIPER (See page BR−25 )
3. REMOVE FLANGE
(a) Using a screwdriver and hammer, remove the grease cap
from the flange.
(b) Using a snap ring expander, remove the snap ring.
(c) Loosen the 6 mounting nuts.
(d) Using a brass bar and hammer, tap on the 6 bolts heads and remove the 6 cone washers, plate washers and nuts.
(e) Remove the flange.
(f) Remove the gasket.
4. REMOVE AXLE HUB WITH DISC
(a) Using a screwdriver, release the lock washer.
(b) Using SST, remove the lock nut. SST 09607−60020
(c) Remove the lock washer.
(d) Using SST, remove the adjusting nut and thrust washer.
SST 09607−60020
(e) Remove the hub and disc together with the outer bearing.
5. REMOVE OIL SEAL AND INNER BEARING
(a) Using SST, remove the oil seal. SST 09308−00010
(b) Remove the inner bearing from the hub.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010