Grease TOYOTA LAND CRUISER 1996 J80 User Guide

BR1D4−01
−
BRAKE REAR BRAKE CALIPER
BR−37
1996 LAND CRUISER (RM451U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR−35 ).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arro\
ws (See page BR−33).
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BR1DA−01
BR−44
−
BRAKE PARKING BRAKE
1996 LAND CRUISER (RM451U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See
page BR−40 ).
NOTICE:
Apply high temperature grease and lithium soap base gly-
col grease to the parts indicated by the arrows (See page
BR−39 ).
1. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Disconnect the PKB cable from bellcrank and remove the 2 tension springs.
(b) Loosen the stopper bolt.
(c) Temporarily install the hub nuts.
(d) Remove the hole plug.
(e) Turn the adjuster and expand the shoes until the disc
locks.
(f) Return the adjuster 8 notches.
(g) Install the hole plug.
2. ADJUST BELLCRANK
(a) Pull the bellcrank until all play in the interior linkage is tak-
en up.
(b) Screw in the bellcrank adjusting bolt to where it contacts on the dust seal.
(c) Loosen it one turn, and lock it at that position with the lock nut.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Install the bellcrank spring.
(e) Connect the PKB cable to the bellcrank.
3. BEDDING DOWN PARKING BRAKE SHOES AND
DISC
(a) Drive the vehicle at about 50 km/h (31 mph) on a safe, lev-
el and dry road.
(b) With the parking brake release button pushed in, pull on the lever with 88 N (9 kgf, 19.8 lbf) of force.
(c) Drive the vehicle for about 400 meters (0.25 mile) in this condition.
(d) Repeat this procedure 2 or 3 times.
4. RECHECK AND ADJUST PARKING BRAKE LEVER TRAVEL
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BR1DG−01
BR0070
−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)BR−51
1996 LAND CRUISER (RM451U)
REASSEMBLY
1. ASSEMBLE THESE PARTS TO LOAD SENSING
SPRING:
Load sensing valve boot
Load sensing spring boot
4 bushings
2 rubber plates
2 collars
HINT:
Apply lithium soap base glycol grease to the parts indicated by
the arrrows. Do not mistake the valve side for the shackle side
of the load sensing spring.
2. INSTALL SHACKLE NO.1 AND NO.2 TO LOAD SENS-
ING SPRING
(a) Install the lock nut and shackle No. 1 to the shackle No. 2.
(b) Torque the bolt and nut through the 2 plate washers. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
3. INSTALL LOAD SENSING SPRING TO VALVE BODY
Install the load sensing spring assembly to the load sensing
valve with the clip.
4. INSTALL VALVE BRACKET
(a) Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body
mounting nuts.
(b) Torque the bolt and nut through the 2 plate washers. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
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R04759
R04775
BR3795
OKNG
-
DIAGNOSTICS ANTI-LOCK BRAKE SYSTEM
DI-214
1996 LAND CRUISER (RM451U)
4 Check sensor rotor and sensor installation.
Front
PREPARATION:
Remove front axle hub and knuckle spindle (See page
SA-8).
CHECK:
Check the sensor rotor serrations.
OK:
No scratches or missing teeth.
CHECK:
Check the sensor tip and grease.
OK:
No scratches or foreign objects on the sensor tip and
grease.
Rear
PREPARATION:
Remove the rear brake caliper and disc.
CHECK:
Check the sensor rotor serrations.
OK:
No scratches or missing teeth.
CHECK:
Check the sensor tip.
OK:
No scratches or foreign objects on the sensor tip.
CHECK:
Check the speed sensor installation.
OK:
The installation bolt is tightened properly and there is
no clearance between the sensor and steering
knuckle or rear axle carrier.
NG Replace speed sensor or rotor.
NOTICE:
Check the speed sensor signal last (See page DI-189).
OK
Check and replace ABS ECU.
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EM−50
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
2. REPLACE SPARK PLUG TUBE GASKETS
(a) Using a screwdriver, pry out the tube gasket.
(b) Using SST and a hammer, tap in a new tube gasket as
shown in the illustration.
SST 09950 −60010 (09951 −00480), 09950 −70010
(09951 −07150)
(c) Apply a light coat of MP grease to the gasket lip.
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P04907
P08469
SST
EM−100
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
2. REPLACE OVERSIZED (O/S) PISTONS FOR CYLIN-
DER BORING
HINT:
Bore all the 6 cylinders for the O/S piston outside diame-
ter.
Replace all the piston rings with ones to match the O/S
pistons.
(a) Keep 6 new O/S pistons. O/S piston diameter:
O/S 0.50100.450 − 100.480 mm (3.9547 − 3.9559 in.)
O/S 1.00100.950 − 100.980 mm (3.9744 − 3.9756 in.)
(b) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 42 mm (1.65 in.) from
the piston head.
(c) Calculate the amount of each cylinder is to be rebored as
follows:
Size to be rebored = P + C − H
P = Piston diameter
C = Piston oil clearance
0.040 − 0.060 mm (0.0016 − 0.0024 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
(d) Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
3. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the timing chain cover is removed from the cylinder block:
(1) Using a screwdriver and a hammer, tap out the oilseal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the timing chain cover edge.
SST 09316−60011 (09316 −00011, 09316−00051)
(3) Apply MP grease to the oil seal lip.
NOTICE:
Do not let foreign matter get onto the lip of the oil seal.
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P05005
P08506
SST
P04518
P04970
SST
P08643
Cut Position
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−101
1996 LAND CRUISER (RM451U)
(b) If the timing chain cover is installed to the cylinder block:
(1) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(2) Apply MP grease to a new oil seal lip.
NOTICE:
Do not let foreign matter get onto the lip of the oil seal.
(3) Using SST and a hammer, tap in the oil seal until its
surface is flush with the timing chain cover edge.
SST 09316−60011 (09316 −00011, 09316−00051)
4. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the rear oil seal retainer is removed from the cylinder block:
(1) Using a screwdriver and a hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal edge.
SST 09223−15030, 09950 −70010 (09951−07150)
NOTICE:
Do not let foreign matter get onto the lip of the oil seal.
(b) If the rear oil seal retainer is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
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P22572
P22574B13834
Drain Plug
Drain Plug
MA0621B13835
Lubricating Positions: 1. Spider2. Slide Yoke1
2 1
MA−8
−
MAINTENANCE CHASSIS
48
Author: Date:
1996 LAND CRUISER (RM451U)
7. REPLACE TRANSFER AND DIFFERENTIAL OIL
(a) Remove the drain plug and drain the oil.
(b) Reinstall the drain plug securely.
(c) Add new oil until it begins to run out of the filler hole.
Oil drade and viscosity: See step 5.
Oil capacity:
Transfer oil
1.7 liters (1.8 US qts, 1.5 lmp. qts)
Front differential oil (w/o Differential lock)
2.8 liters (3.0 US qts, 2.5 lmp. qts)
Front differential oil (w/ Differential lock)
2.65 liters (2.8 US qts, 2.3 lmp. qts)
Rear differential oil
3.25 liters (3.4 US qts, 2.9 lmp. qts)
8. REPACK FRONT WHEEL BEARINGS (See pages SA−7 and SA−9 )
9. LUBE STEERING KNUCKLE CHASSIS AND PROPEL-
LER SHAFT
(a) Remove the screw plug from each steering knuckle and repack with lubricant.
Steering knuckle grease:
Molybdenum disulfide lithium base chassis grease
(NLGI No. 2)
(b) Reinstall the 2 screw plugs.
(c) Lubricate chassis components, referring to the lubrication
chart. Before pumping in grease, wipe off any mud and
dust on the grease fitting.
Grease grade:
Lithium base chassis grease (NLGI No. 2)
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PP2YW−01
−
PREPARATION BODY
PP−69
1996 LAND CRUISER (RM451U)
LUBRICANT
ItemCapacityClassification
MP grease−−
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PR06O−02
Q10862
 Spider Grease Fitting
 Snap Ring
 Spider Bearing
Dust Cover
Grease Fitting Propeller Shaft
Flange Yoke
 Snap Ring
 Spider Bearing

Spider
Sleeve Yoke
N·m (kgf·cm, ft·lbf)
 Non− reusable part
Flange Yoke
Propeller Shaft
 Spider
Grease Fitting
Dust Cover

Spider Bearing

Snap Ring
Grease Fitting
Sleeve Yoke
: Specified torque
Flange Yoke
Flange Yoke
Front Propeller Shaft
74 (750, 54)
88 (900, 65)
74 (750, 54)
74 (750, 54)
74 (750, 54)
74 (750, 54)
88 (900, 65)
88 (900, 65)
88 (900, 65)
Rear propeller Shaft
 Spider
 Spider Bearing 
Snap Ring
Grease
Fitting
Grease Fitting
PR−2
−
PROPELLER SHAFT PROPELLER SHAFT ASSEMBLY
850
Author: Date:
1996 LAND CRUISER (RM451U)
PROPELLER SHAFT ASSEMBLY
COMPONENTS
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