Position TOYOTA LAND CRUISER 1996 J80 Workshop Manual

Z06898
SA2458
Matchmarks
SA2467SST
Z10281SST
SA2308
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−41
1996 LAND CRUISER (RM451U)
14. w/o DIFFERENTIAL LOCK:
INSTALL ADJUSTING NUTS
Install the adjusting nuts on the carrier , making sure the nuts are
threaded properly.
15. INSTALL BEARING CAPS
Align the matchmarks on the cap and carrier. Screw in the 2
bearing cap bolts 2 or 3 turns and press down the bearing cap
by hand.
HINT:
If the bearing cap does not fit tightly on the carrier , the adjusting
nuts are not threaded properly.
Reinstall the adjusting nuts if necessary.
16. ADJUST SIDE BEARING PRELOAD
(a) Torque the 4 bearing cap bolts to the specified torque, and loosen them to the point where the adjusting nuts can
be turned by SST.
SST 09504−00011
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(b) Fully tighten the 4 bearing cap bolts by hand.
(c) Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008
in.).
(d) With turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side. After the bearings
are settled, loosen the adjusting nut on the drive pinion
side.
(e) Place a dial indicator on the top of the adjusting nut on the ring gear side.
(f) Adjust the side bearing for zero preload by tightening the
other adjusting nut until the pointer on the indicator be-
gins to move.
(g) Torque the adjusting nut 1 − 1.5 notches from the zero preload position.
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SA2443SST
SA2403
SA2463
FA2013
Proper ContactHeel Contact
Face Contact
Select an adjusting washer that will bring the drive
pinion closer to the ring gear.
Select an adjusting washer that will shift the drive
pinion away from the ring gear.
Toe Contact
Flank Contact
SA−42
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
(h) Using a dial indicator, adjust the ring gear backlash until
it is within the specification.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
HINT:
The backlash is adjusted by turning the left and right adjusting
nuts equal amounts. For example, loosen the nut on the left
side one notch and torque the nut on the right side one notch.
(i) Torque the 4 bearing cap bolts. Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(j) Recheck the ring gear backlash. Backlash: 0.13 −0.18 mm (0.0051 −0.0071 in.)
(k) Using a torque wrench, measure the preload. Total preload (at starting):
Drive pinion preload plus
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
17. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead.
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth pattern.
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SA1VA−01
R13157
Brass Bar
Positions
R13158
SST
R13159
SA−68
−
SUSPENSION AND AXLE REAR AXLE HUB
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REMOVE OIL SEAL AND INNER BEARING
(a) Using SST, remove the oil seal.
SST 09308−00010
(b) Remove the inner bearing from the hub.
2. REMOVE BEARING OUTER RACE
Using a brass bar and hammer, remove the bearing outer
races.
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
3. INSTALL BEARING OUTER RACE
Outside race:
Using SST and a press, install new bearing outer races.
SST 09950−60020 (09951 −00710),
09950 −70010 (09951 −07150)
Inside race:
Using SST and a press, install new bearing outer races.
SST 09950−60020 (09951 −00810),
09950 −70010 (09951 −07150)
4. PACK BEARINGS WITH MP GREASE
(a) Place MP grease on the palm of your hand.
(b) Pack grease into the bearing until the grease ooze out from the other side.
(c) Do the same around the bearing circumference.
5. COAT INSIDE OF HUB WITH MP GREASE
6. INSTALL INNER BEARING AND OIL SEAL
(a) Place inner bearing into the hub.
(b) Using SST, install a new oil seal into the hub. SST 09223−15020, 09950 −70010 (09951−07150)
(c) Apply MP grease to the oil seal lip.
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SA1VB−01
R08001
Lock Nut Mark
Axle Housing
Mark
−
SUSPENSION AND AXLE REAR AXLE HUB
SA−69
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL REAR AXLE HUB
(a) Clean the hub installation position of the axle housing and
apply MP grease thinly.
(b) Place the axle hub to the axle housing.
NOTICE:
Be careful not to damage the oil seal.
(c) Install the outer bearing.
2. INSTALL LOCK NUT PLATE AND REAR AXLE BEAR- ING LOCK NUT
(a) Place the lock nut plate on the axle housing, making sure
the tongue lines up with the key groove.
(b) Temporarily install the lock nut.
3. INSTALL DISC
Install the disc to the rear axle hub and temporarily install the
2 hub nuts.
4. ADJUST PRELOAD
(a) Using SST, torque the bearing lock nut.SST 09509−25011
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
(b) Make the bearing smooth by turning the hub several
times.
(c) Using the SST, retighten the bearing lock nut. Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
(d) Using the SST, loosen the nut until it can be turned by
hand.
(e) Using a spring tension gauge, check the preload and tighten the nut until the preload is within the specification.
Preload (at starting):
26−57 N (2.6−5.8 kgf, 5.7−12.8 lbf)
NOTICE:
Make sure that there is no contact with the parking brake
shoe.
(f) Align the mark on the bearing lock nut and tip of axle housing under the above preload range.
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SA24T−01
SA2310
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−79
1996 LAND CRUISER (RM451U)
REMOVAL
1. w/ Differential lock:
SHIFT REAR DIFFERENTIAL TO LOCK
(a) Turn the ignition switch to the ON position.
(b) Keep the center differential lock condition.
(c) Turn the differential lock control switch to the RR or FR/ RR position and lock the rear differential.
HINT:
Rotating the tires, check they are in the differential lock condi-
tion.
(d) Disconnect the cable from the negative terminal of the battery.
2. DRAIN DIFFERENTIAL OIL
3. REMOVE REAR AXLE SHAFTS (See page SA−63 )
4. DISCONNECT PROPELLER SHAFT (See page PR−3 )
5. REMOVE DIFFERENTIAL CARRIER ASSEMBLY
(a) Remove the 10 nuts, washers and differential carrier as- sembly.
NOTICE:
Be careful not to damage the installation surface. Torque: 73 N·m (740 kgf·cm, 54 ft·lbf)
(b) Remove the gasket.
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W00493
30 mm
(1.18 in.)
SA1VH−04
SA2446
SA−80
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the vertical and lateral runout of
the companion flange. Maximum runout: 0.10 mm (0.0039 in.)
2. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout. Maximum runout: 0.10 mm (0.0039 in.)
If the runout is greater than the maximum, replace the ring gear.
3. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash. Backlash: 0.15 − 0.20 mm (0.0059 − 0.0079 in.)
HINT:
Perform the measurements at 3 or more positions around the
circumference of the ring gear.
If the backlash is not within the specification, adjust the side
bearing preload or repair as necessary.
4. MEASURE DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear.
Preload (at starting):
0.7 − 1.0 N·m (7 − 10 kgf·cm, 6.1 − 8.7 in.·lbf)
(b) Using a torque wrench, measure the preload. Total preload (at starting):
Drive pinion preload plus
w/o Differential lock
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
w/ differential lock
0.3 − 0.7 N·m (3 − 7 kgf·cm, 2.6 − 6.1 in.·lbf)
If necessary, disassemble and inspect the differential.
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Z06918
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−95
1996 LAND CRUISER (RM451U)
(g) Using the SST, torque the adjusting nut 1−1.5 notches
from the zero preload position.
(h) Using a dial indicator, adjust the ring gear backlash until it is within the specification.
Backlash: 0.15 − 0.20 mm (0.0059−0.0079 in.)
HINT:
The backlash is adjusted by turning the left and right adjusting
nuts equal amounts. For example, loosen the nut on the left
side one notch and torque the nut on the right side one notch.
(i) Torque the 4 bearing cap bolts. Torque:78 N·m (800 kgf·cm, 58 ft·lbf)
(j) Recheck the ring gear backlash. Backlash: 0.15 − 0.20 mm (0.0059−0.0079 in.)
17. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus
w/o Differential lock
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
w/ Differential lock
0.3− 0.7 N·m (3 − 7 kgf·cm, 2.6 − 6.1 in.·lbf)
18. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear
with red lead.
(b) Turn the companion flange, pin both directions to inspect the ring gear for proper tooth contact.
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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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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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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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