Front diff TOYOTA LAND CRUISER 1996 J80 Owner's Guide

SA1960
SST
RA1072
Filler Hole
Oil
0 − 5 mm (0 − 0.20 in.)
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL REAR OIL SEAL
SA−23
1996 LAND CRUISER (RM451U)
(c) Apply light coat of gear oil on threads of a new companion
flange nut.
(d) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 196 N·m (2,000 kgf·cm, 145 ft·lbf)
14. ADJUST DRIVE PINION PRELOAD (See page SA−36 )
15. STAKE DRIVE PINION NUT
16. INSTALL FRONT PROPELLER SHAFT (See page PR−5 )
17. FILL DIFFERENTIAL WITH GEAR OIL Torque: 49 N·m (500 kgf·cm, 39 ft·lbf)
Oil type: Hypoid gear oil API GL −5
Recommended oil viscosity:
Above −18°C (0° F) SAE 90
Below −18°C (0° F) SAE 80W−90 or 80W
Capacity:
w/o Differential lock:
2.80 liters (2.9 US qts, 2.5 Imp. qts)
w/ Differential lock:
2.65 liters (2.8 US qts, 2.3 Imp. qts)
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SA1UL−01
SA−24
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
881
Author: Date:
1996 LAND CRUISER (RM451U)
FRONT DIFFERENTIAL CARRIER
COMPONENTS
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W00530
w/o Differential LockSide Gear Thrust WasherPinion Gear
Pinion Gear Thrust Washer
 Dust Deflector
Front Bearing Outer Race
 Oil Seal
Companion Flange
Bearing Cap
Differential Carrier

Adjusting Nut Lock Oil Slinger
Differential Case
Drive Pinion
Ring Gear
Side Baring
Straight Pin
Adjusting Nut
 Bearing Spacer


Oil Storage Ring
Outer Race
Outer Race
 Non− reusable part 
Lock Plate
x 10
x 5 Pinion Shaft
Pinion Gear
Pinion Washer
Rear Bearing
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−25
882
Author: Date:
1996 LAND CRUISER (RM451U)
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W00531
w/ Differential LockSide Gear
Thrust Washer
Pinion Gear
Thrust Washer
Outer Race

Oil Seal Companion Flange
Bearing Cap
Differential Carrier
 Adjusting Nut Lock Oil Slinger
Drive Pinion
Ring Gear
Side Baring
Adjusting Nut

Bearing Spacer

Oil Storage Ring
Outer Race
 Non− reusable part

Lock Plate x 8
x 4 
O− Ring
Pinion Washer
Rear Bearing

 Dust Deflector
Front Bearing Outer Race
Adjusting Nut
Sleeve
Spider Side GearLH Differential Case
RH Differential Case
x 8
 Precoated part 
Gasket Indicator Switch
Actuator

Straight Screw Plug
Spring Seat
Compression Spring
Ball

Shaft Retainer Shift Fork Shaft Shift Fork

Slotted Spring Pin
Pinion Gear
SA−26
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
883
Author: Date:
1996 LAND CRUISER (RM451U)
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SA1UM−03
FA2038
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−27
1996 LAND CRUISER (RM451U)
REMOVAL
1. w/ DIFFERENTIAL LOCK:
BEFORE REMOVAL, SHIFT FRONT 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 FR/RR posi-
tion and lock the front differential.
(d) Rotating the tires, check they are in the differential lock condition.
(e) Disconnect the cable from the negative terminal of the battery.
2. DRAIN DIFFERENTIAL OIL
3. REMOVE FRONT AXLE SHAFTS (See page SA−13)
4. REMOVE TIE ROD FROM KNUCKLE ARM (See page SA−13 )
5. REMOVE FRONT PROPELLER SHAFT (See page PR−3 )
6. w/ DIFFERENTIAL LOCK: DISCONNECT CONNECTORS AND TUBE
HINT:
When connecting the tube of the harness side to the hose
of the actuator side, its depth of insertion is 15 mm (0.59
in.).
Take care that water or equivalent does not adhere to the
connector and hose.
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Z10092
w/o Differential Lock
w/ Differential Lock
SA−28
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
7. 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: 27 N·m (280 kgf·cm, 20 ft·lbf)
(b) Remove the gasket.
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W00493
30 mm
(1.18 in.)
SA1UN−03
SA2465
SA2462
SA2403
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−29
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
and driven pinion as a set.
3. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 −0.18 mm (0.0051 −0.0071 in.)
If the backlash is not within the specification, adjust the side
bearing preload or repair as necessary.
4. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of backlash be-
tween the drive pinion and ring gear. Preload (at starting):
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
5. CHECK TOTAL PRELOAD
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)
If necessary, disassemble and inspect the differential.
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SA2442
R13332
SA2206
Z10098
SA−30
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
6. w/o DIFFERENTIAL LOCK:
CHECK SIDE GEAR BACKLASH
Using a dial indicator, measure the side gear backlash with
holding one pinion gear toward the case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washers (See page .SA−35 ).
7. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See page SA−35 )
8. w/ DIFFERENTIAL LOCK: REMOVE ACTUATOR
(a) Remove the bolt and actuator from the differential carrier.
(b) Remove the O−ring.
9. w/ DIFFERENTIAL LOCK: REMOVE INDICATOR SWITCH
Remove the indicator switch and gasket.
10. w/ DIFFERENTIAL LOCK:
REMOVE SHIFT FORK SHAFT
(a) Using a hexagon wrench, remove the 2 straight screw plugs.
(b) Remove the spring seat, compression spring and ball.
(c) Using a pin punch and hammer , remove the slotted spring
pin.
(d) Remove the 2 bolts from the shaft retainer.
(e) Using a plastic hammer, tap out the shaft retainer.
(f) Remove the shift fork shaft.
HINT:
Pull out the shift fork shaft with a screwdriver turned round.
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SA2405
SST
R13141
SST
SA2402
SST
Z00641
SST
R13142
Matchmarks
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−31
1996 LAND CRUISER (RM451U)
11. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake the nut.
(b) Using SST to hold the flange, remove the nut and plate
washer.
SST 09330−00021
(c) Using SST, remove the companion flange. SST 09950 −30010 (09951 −03010, 09953 −03010,
09954 −03010, 09955 −03030, 09956−03020)
12. REMOVE OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal from the dif ferential carrier.
SST 09308−10010
(b) Remove the oil slinger.
13. REMOVE REAR BEARING
Using SST, remove the rear bearing from the drive pinion. SST 09556−22010
14. REMOVE DIFFERENTIAL CASE
(a) Place matchmarks on the bearing cap and dif ferential car-
rier.
(b) Remove the 2 adjusting nut locks.
(c) Remove the 4 bolts and 2 bearing caps.
(d) w/o Differential lock: Remove the 2 adjusting nuts.
(e) w/o Differential lock: Remove the differential case with the side bearing outer
races from the carrier.
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FA2045
SST
SA2431
SST
Rear Bearing Outer Race
SA2410
Oil Strage Ring
Front Bearing
Outer Race
SA−32
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
1996 LAND CRUISER (RM451U)
HINT:
Tag the disassembled parts to show the location for reassemb-
ly.
(f) w/ Differential lock:
Remove the differential case with the side bearing outer
race, adjusting nuts and sleeve from the differential carri-
er.
(g) w/ Differential lock: Remove the shift fork.
15. REMOVE DRIVE PINION AND BEARING SPACER
(a) Remove the drive pinion with the front bearing.
(b) Remove the bearing spacer.
16. REMOVE DRIVE PINION FRONT BEARING
(a) Using SST and a press, remove the bearing from the drive
pinion.
SST 09950−00020
HINT:
If the drive pinion or ring gear are damaged, replace them as
a set.
(b) Remove the plate washer from the drive pinion.
17. REMOVE FRONT AND REAR BEARING OUTER
RACES AND OIL STORAGE RING
(a) Using SST, remove the rear bearing outer race. SST 09308−00010
(b) Using a brass bar and hammer, remove the oil storage ring and front bearing outer race.
HINT:
Do not remove the oil storage ring unless replacing it with a new
one.
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