TOYOTA LAND CRUISER 1996 J80 Workshop Manual

TF0862
SST
TR0CN−01
TF0863
SST
TF0864
SST
SST
TR−10
−
TRANSFER TRANSFER ASSEMBLY
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REPLACE SHIFT LEVER OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal. SST 0608−00081, 09950 −70010 (09951−07150)
2. REPLACE INPUT SHAFT OIL SEAL
(a) Using SST and a hammer, drive out the oil seal. SST 09316−60011 (09316 −00011)
(b) Using SST and a hammer, drive in a new oil seal. SST 09316−60011 (09316 −00011, 09316−00031)
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TR0B4−01
−
TRANSFER TRANSFER ASSEMBLY
TR−11
1996 LAND CRUISER (RM451U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page TR−4 ).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before assem\
bly.
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TR0B5−01
TR−12
−
TRANSFER INPUT SHAFT
822
Author: Date:
1996 LAND CRUISER (RM451U)
INPUT SHAFT
COMPONENTS
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TR0B6−01
TF0870
Socket
Wrench
−
TRANSFER INPUT SHAFT
TR−13
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE REAR BALL BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a socket wrench and press, remove the rear ball
bearing.
2. REMOVE INPUT GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the input gear.
3. REMOVE FRONT BALL BEARING
Using a press, remove the front ball bearing.
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TR0B7−01
Q00533
TR−14
−
TRANSFER INPUT SHAFT
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL FRONT BALL BEARING
Using SST and a press, install a new front ball bearing. SST 09527−30010
2. INSTALL INPUT GEAR
(a) Using a press, install the input gear.
(b) Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.00 (0.0787)F2.50 (0.0984)
B2.10 (0.0827)G2.60 (0.1024)
C2.20 (0.0866)H2.70 (0.1063)
D2.30 (0.0906)J2.80 (0.1 102)
E2.40 (0.0945)−−
(c) Using a snap ring expander, install a new snap ring.
3. INSTALL REAR BALL BEARING
(a) Using SST and a press, install a new rear ball bearing.
SST 09316−60011 (09316 −00031)
(b) Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)
A2.00 (0.0787)
B2.10 (0.0827)
C2.20 (0.0866)
D2.30 (0.0906)
E2.40 (0.0945)
(c) Using a snap ring expander, install a new snap ring.
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TR0B8−01
Z15264
Front Taper Roller BearingIdler Gear
High and Low
Clutch SleeveNeedle Roller Bearing
Idler
Low Gear Rear Taper
Roller Bearing
−
TRANSFER IDLER GEAR
TR−15
825
Author: Date:
1996 LAND CRUISER (RM451U)
IDLER GEAR
COMPONENTS
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TR0B9−01
TF0887
TF0888
Q07132
SST
Q07100
Socket Wrench
TR−16
−
TRANSFER IDLER GEAR
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. INSPECT IDLER LOW GEAR RADIAL AND THRUST
CLEARANCE
(a) Using a feeler gauge, measure the idler low gear thrust clearance.
Standard clearance:
0.125−0.275 mm (0.0049 −0.0108 in.)
Maximum clearance:
0.275 mm (0.0108 in.)
(b) Using a dial indicator, measure the idler low gear radial clearance.
Standard clearance:
0.015−0.068 mm (0.0006 −0.0027 in.)
Maximum clearance:
0.068 mm (0.0027 in.)
2. REMOVE FRONT TAPER ROLLER BEARING
Using SST, remove the front taper roller bearing. SST 09950−40010
3. REMOVE REAR TAPER ROLLER BEARING
Using SST, a press and socket wrench, remove the rear taper
roller bearing. SST 09950−00020
4. REMOVE IDLER LOW GEAR AND NEEDLE ROLLER BEARING FROM IDLER GEAR
5. REMOVE HIGH AND LOW CLUTCH SLEEVE FROM IDLER GEAR
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TR0BA−01
TF0893
SST
Q00538
TF0896
SST
−
TRANSFER IDLER GEAR
TR−17
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL FRONT TAPER ROLLER BEARING
Using SST and a press, install the front taper roller bearing.
SST 09316−60011 (09316 −00011, 09316−00031)
2. INSTALL HIGH AND LOW CLUTCH SLEEVE
HINT:
Make sure to install the high and low clutch sleeve in the correct
direction.
3. INSTALL NEEDLE ROLLER BEARING AND IDLER LOW GEAR TO IDLER GEAR
(a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing and idler low gear.
4. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing. SST 09316−60011 (09316 −00011, 09316−00071)
5. INSPECT IDLER LOW GEAR RADIAL AND THRUST CLEARANCE
(See page TR−16 )
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TR0BB−01
Q07134
Front Drive Gear
PieceHigh
Speed Output GearHigh Speed Output
Gear Bushing
Clutch HubHigh and Low
Clutch Sleeve Rear Taper Roller
Bearing
 Snap Ring
Needle Roller Bearing
Thrust Washer
Thrust Washer Rear Side Gear
Straight Pin x 12
Differential Rear Case
Thrust Washer
Pinion
Gear
Pinion Shaft
Front Side Gear
Thrust Washer
Differential Front Case
 Non− reusable part Low Gear
Straight Pin

Snap Ring Front T
aper Roller BearingNeedle Roller Bearing
Pinion Gear
TR−18
−
TRANSFER CENTER DIFFERENTIAL
828
Author: Date:
1996 LAND CRUISER (RM451U)
CENTER DIFFERENTIAL
COMPONENTS
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TR0BC−01
TF0900
TF0944
Q07101
SST
Q07102
SST
Q07103
SST
−
TRANSFER CENTER DIFFERENTIAL
TR−19
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND
THRUST CLEARANCE
(a) Using a feeler gauge, measure the high speed output gear thrust clearance.
Standard clearance:
0.10−0.25 mm (0.0039 −0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)
(b) Using a dial indicator, measure the high speed output gear radial clearance.
Standard clearance:
0.035−0.091 mm (0.0014 −0.0036 in.)
Maximum clearance:
0.091 mm (0.0036 in.)
2. REMOVE FRONT DRIVE GEAR PIECE
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the front drive gear piece.
SST 09950−00020, 09950 −60010 (09951−00320)
NOTICE:
Be careful not to drop the center differential assembly.
3. REMOVE FRONT TAPER ROLLER BEARING
Using SST and a press, remove the front taper roller bearing.
SST 09950−00020
4. REMOVE HIGH SPEED OUTPUT GEAR
5. REMOVE NEEDLE ROLLER BEARING
6. REMOVE HIGH AND LOW CLUTCH SLEEVE AS-
SEMBLY
7. REMOVE HIGH SPEED OUTPUT GEAR BUSHING AND CLUTCH HUB
(a) Using SST and a press, remove the high speed output
gear bushing and clutch hub.
SST 09550−00020, 09950 −00030, 09950−60010
(09951 −00320)
(b) Using a magnetic finger, remove the straight pin from the
differential front case.
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