TOYOTA LAND CRUISER 1996 J80 Workshop Manual

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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SA1VK−01
SA−100
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−79 ).
HINT:
After installation, fill the differential with gear oil (See page SA−27).
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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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W02075
Heater Main Relay
5 Relay Housing
Metallic Parts
3
2
41
Z07257
Free−Lock
Lock−Free
Heater
Main
Relay Battery Battery
Heater
Main
Relay
SA−104
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
961
Author: Date:
1996 LAND CRUISER (RM451U) 3 (M1) −
1 (M2)
OFF − RR
0.5 or less →
10 − 14.5
(Approx. 1 sec) → 0.5 or less
1 (M2) − 3 (M1)RR − OFF
0.5 or less →
10 − 14.5
(Approx. 1 sec) → 0.5 or less
7 (M3) − 5 (M4)OFF or RR − FR RR
0.5 or less →
10 − 14.5
(Approx. 1 sec) → 0.5 or less
5 (M4) − 7 (M3)FR RR − RR or OFF
0.5 or less →
10 − 14.5
(Approx. 1 sec) → 0.5 or less
If the circuit is not as specified, replace the ECU.
(d) Install the ECU in place.
3. INSPECT DIFF. LOCK ACTUATOR
(a) Jack up the vehicle.
(b) Use the heater main relay and connect it, as shown below.
NOTICE:
Connect the terminals being careful not to touch the neigh-
boring terminals or metallic parts of relay housing.
(c) Rotate the tire and check that differential lock has oc- curred.
If operation is not as specified, replace the actuator.
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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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SA1VM−01
SA−106
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
1996 LAND CRUISER (RM451U)
DIFFERENTIAL LOCKING SYSTEM
LOCATION
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SA1VN−02
Z07258
Z07261
SA2619
−
SUSPENSION AND AXLE DIFFERENTIAL LOCKING SYSTEM
SA−107
1996 LAND CRUISER (RM451U)
REMOVAL
1. REMOVE FRONT ACTUATOR
(a) Shifting the front differential lock.
(b) Disconnect the connector and tube.
(c) Remove the 2 nuts, bolt and actuator.
(d) Remove the O−ring from the actuator.
2. REMOVE REAR ACTUATOR
(a) Shifting the gear differential lock.
(b) Remove the actuator protector.
Remove the 2 nuts, bolt and protector.
(c) Disconnect the connectors and tube.
(d) Remove the rear Diff. lock position switch.
(e) Remove the cover. (1) Remove the 3 bolts.
(2) Using a brass bar and hammer, remove the cover.
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