TOYOTA LAND CRUISER 1996 J80 Workshop Manual

TR0BI−01
Q00530
Q08384
Q02549
Q07138
TR−30
−
TRANSFER REAR EXTENSION HOUSING
1996 LAND CRUISER (RM451U)
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.
6. REMOVE CENTER DIFFERENTIAL CONTROL COU- PLING ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the coupling assembly from the rear extension housing.
7. REMOVE SEPARATOR AND OIL PUMP PLATE
Remove the 3 bolts, separator and oil pump plate.
8. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the vehicle speed sensor drive gear.
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TF0959
SST
Q08385
Q08481
SST
−
TRANSFER REAR EXTENSION HOUSING
TR−31
1996 LAND CRUISER (RM451U)
9. 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.
10. 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.
11. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal from the rear extension
housing.
12. REMOVE BALL BEARING
(a) Using a screwdriver, remove the snap ring.
(b) Using SST and a press, remove the ball bearing to the rear extension housing.
SST 09316−60011 (09316 −00011, 09316−00021)
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TR0BJ−01
Q02615
Q02616
Q02617
TR−32
−
TRANSFER REAR EXTENSION HOUSING
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT DRIVEN ROTOR BODY CLEARANCE
(a) Install the drive rotor to the driven rotor.
(b) Using a feeler gauge, measure the body clearance be- tween the drive rotor and extension housing.
Standard body clearance:
0.08−0.17 mm (0.0031 −0.0067 in.)
Maximum body clearance: 0.17 mm (0.0067 in.)
If the body clearance exceeds the maximum, replace the drive
rotor or driven rotor.
2. INSPECT DRIVEN ROTOR TIP CLEARANCE
Using a feeler gauge, measure the tip clearance between the
driver rotor and driven rotor. Standard tip clearance:
0.05−0.15 mm (0.0020 −0.0059 in.)
Maximum tip clearance: 0.15 mm (0.0059 in.)
If the tip clearance exceeds the maximum, replace the drive ro-
tor or driven rotor.
3. INSPECT OIL PUMP SIDE CLEARANCE
Using a steel straight edge and feeler gauge, measure the side
clearance of oil pump. Standard side clearance:
0.03−0.10 mm (0.0012 −0.0039 in.)
Maximum side clearance: 0.10 mm (0.0039 in.)
If the side clearance exceeds the maximum, replace the drive
rotor or driven rotor.
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TR0CO−01
TF0964
SST
TF0962
Q08482
SST
TF0967
SST
Q08482
SST
−
TRANSFER REAR EXTENSION HOUSING
TR−33
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL BALL BEARING
(a) Using SST and a press, install the ball bearing.
SST 09316−60011 (09316 −00011, 09316−00031)
(b) Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)
A1.7 (0.0669)
B1.8 (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 09316−60011 (09316 −00011, 09316−00041)
(b) Using SST and a press, install a new rear output shaft dust deflector.
SST 09316−20011, 09316 −60011 (09316−00011)
3. INSTALL OIL SEAL
Using SST and a hammer, drive in a new oil seal. SST 09316−60011 (09316 −00011, 09316−00031)
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TF0969
SST
TF0958
Q07138
Q02549
Q08384
TR−34
−
TRANSFER REAR EXTENSION HOUSING
1996 LAND CRUISER (RM451U)
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 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 VEHICLE SPEED SENSOR DRIVE GEAR
(a) Install the vehicle speed sensor drive gear.
(b) Using a snap ring expander, install the snap ring.
6. INSTALL OIL PUMP PLATE AND SEPARATOR
(a) Install the oil pump plate.
(b) Install the separator.
(c) Install and torque the 3 bolts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
7. INSTALL CENTER DIFFERENTIAL CONTROL COU- PLING ASSEMBLY
(a) Install the coupling assembly to the output shaft.
(b) Using a snap ring expander, install the snap ring.
8. 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.
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)
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TF0977
Q00529
−
TRANSFER REAR EXTENSION HOUSING
TR−35
1996 LAND CRUISER (RM451U)
9. INSTALL DRIVEN ROTOR
(a) Apply gear oil to the driven rotor.
(b) Install the driven rotor.
10. INSTALL DRIVE ROTOR
(a) Apply gear oil to the drive rotor.
(b) Install the drive rotor.
HINT:
Align the alignment marks.
11. 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.
12. INSTALL OIL PUMP DRIVE SHAFT
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TR0BL−01
TR−36
−
TRANSFER MOTOR SHIFT CONTROL SYSTEM
846
Author: Date:
1996 LAND CRUISER (RM451U)
MOTOR SHIFT CONTROL SYSTEM
LOCATION
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Q02622
Light upGoes off
L
NH
DIFF LOCK
DIFF LOCK
TR0BM−03
Z15367
Relay Side
V01699
V06651
−
TRANSFER MOTOR SHIFT CONTROL SYSTEM
TR−37
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT SHIFT LEVER POSITION
(a) Start the engine, and turn the center diff lock switch to
OFF.
(b) Check that the center diff indicator light comes on when the transfer shift lever shifted to the ”L” position. Check
that the light goes off when the lever is shifted to the ”N”
or ”H” position.
2. INSPECT CENTER DIFF LOCK CONTROL RELAY
(a) Check that there is continuity between the terminals, as shown in the chart.
HINT:
There is a diode between the terminals 6 and 7. If the circuit
shown no continuity, change the positive (+) and negative ( −)
probes and recheck the circuit.
(b) Apply battery positive voltage between the terminals and check that there is continuity between the terminals, as
shown in the chart.
If continuity is not as specified, replace the relay.
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TR−38
−
TRANSFER MOTOR SHIFT CONTROL SYSTEM
1996 LAND CRUISER (RM451U)
3. INSPECT MOTOR ACTUATOR
(a) Measure the resistance between the terminals 2 and 3.
Standard resistance: 0.3 − 100 Ω
(b) Measure the resistance between the terminals 2 or 3 and
body ground.
Standard resistance: More than 0.5 MΩ
If the resistance value is not as specified, replace the motor ac-
tuator.
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