TOYOTA LAND CRUISER 1998 Factory Repair Manual

Z00641
SST
R15928Matchmarks
FA2045
SST
F05439
Front: Rear:
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
SA-145
2095 Author
: Date
:
2004 LAND CRUISER (RM1071U)
10. REMOVE FRONT BEARING
Using SST, remove the front bearing from the drive pinion.
SST 09556-22010
If the front bearing is damaged or worn, replace the bearing.
11. REMOVE DIFFERENTIAL CASE
(a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 2 bolts and adjusting nut locks.
(c) Remove the 4 bolts, 2 bearing caps and adjusting nuts.
HINT:
Tag the disassembled parts to show the location for reassem-
bling.
(d) Remove the differential case with the bearing outer races.
HINT:
Tag the disassembled parts to show the location for reassem-
bling.
12. REMOVE DRIVE PINION AND BEARING SPACER
(a) Remove the drive pinion with the rear bearing.
(b) Remove the bearing spacer.
13. REMOVE DRIVE PINION REAR BEARING
(a) Using SST and a press, remove the rear bearing from the
drive pinion.
SST 09950-00020
HINT:
If the drive pinion or ring gear is damaged, replace them as a
set.
(b) Remove the plate washer from the drive pinion.
14. REMOVE FRONT AND REAR BEARING OUTER
RACES
Using a brass bar and hammer, remove the outer races.

F05204
Matchmarks
SA3243
F05206
SST
R14029Matchmarks SA-146
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2096 Author
: Date
:
2004 LAND CRUISER (RM1071U)
15. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 ring gear set bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the differential case.
16. CHECK DIFFERENTIAL CASE RUNOUT
(a) Place the bearing outer races on their respective bear-
ings. Check that the right and left outer races are not inter-
changed.
(b) Install the differential case in the differential carrier.
(c) Tighten the adjusting nut just to where there is no play in
the bearing.
(d) Align the matchmarks on the bearing cap and differential
carrier.
(e) Install and uniformly tighten the bearing cap bolts a little
at a time.
(f) Using a dial indicator, measure the differential case run-
out.
Maximum runout: 0.04 mm (0.0016 in.)
(g) Remove the differential case.
17. REMOVE SIDE BEARINGS FROM DIFFERENTIAL
CASE
Using SST, remove the 2 side bearings from the differential
case.
SST 09950-00020, 09950-00030,
09950-4001 1 (09957-04010),
09950-60010 (09951-00480)
18. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the RH and LH cases.
(b) Remove the 8 bolts uniformly, a little at a time.
(c) Using a plastic hammer, separate the RH and LH cases.

- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
SA-147
2097 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(d) Remove the 2 side gears, 6 side gear thrust washers, 4
clutch plates, 2 spring retainers, compression spring, 4
pinion gears, 4 pinion gear thrust washers and spider
from the differential case.
HINT:

Keep the disassembled parts in order.

If the side gear backlash has been adjusted by TOYOTA
dealer, adjusting shims are installed between the side
gear thrust washer and the differential case.

SA161-04
RA0225
Z15288
R13849
RA0192
SA-148
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2098 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSPECTION
1. REPLACE PARTS THAT ARE DAMAGED OR WORN
HINT:
If replacing the side gear, also replace the thrust washer that
contact with it.
2. INSPECT SIDE GEAR THRUST WASHERS FOR WEAR
OR DAMAGE
Using a micrometer, measure that the contact surface of the
thrust washer is even and check that no bare metal is showing.
Thickness (Reference):
1.97 - 2.06 mm (0.0776 - 0.0811 in.)
If necessary, replace the thrust washer.
HINT:
If replacing the thrust washer, also replace the clutch plate that
contacts with it.
3. INSPECT CLUTCH PLATE FOR WEAR OR DAMAGE
Using a micrometer, measure the contact surface of the clutch
plate and check that there is no abnormal wear.
Thickness (Reference):
1.97 - 2.03 mm (0.0776 - 0.0799 in.)
If necessary, replace the clutch plate.
4. INSPECT COMPRESSION SPRING FREE LENGTH
Using vernier calipers, measure the free length of the spring.
Length (Reference): 32.8 mm (1.291 in.)

SA164-10
SA-162
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2112 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-141).
HINT:
After installation, fill the differential with hypoid gear oil for LSD (See page SA-95), fill the brake reservoir
with brake fluid, bleed the brake system (See page BR-4), check for leaks and check the ABS speed sensor
signal (See page DI-505).

SA1DA-04
F05258
RH Case:LH Case:
X
X
F05259
SST
Y SA-150
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2100 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:

When reusing the side gear, thrust washers and clutch
plates, skip the STEP 1.

Using a shop rag, clean off any foreign object from the
parts.

Apply all of the sliding and rotating surfaces with LSD oil.
1. SELECT ADJUSTING SHIM
(a) Measure the RH and LH differential case dimensions ºXº,
as shown in the illustration.
(b) Install the thrust washers and clutch plates on the side
gear.
(c) Using SST to press down the thrust washers and clutch
plates with about pressure of 10 kgf (22 lbf), measure di-
mension ºYº, as shown in the illustration.
SST 09649-17010
(d) Referring to the following selection table on the next
page, select the proper adjusting shim.
Adjust shim thickness =
X - Y - 19.08 mm (0.7511 in.)

F05260
46.05 46.06 46.07 46.08 46.09 46.10 46.11 46.12 46.13 46.14 46.15 46.16 46.17 46.18 46.19 46.20 46.21 46.22
26.45
26.46
26.47
26.48
26.49
26.50
26.51
26.52
26.53
26.54
26.55
26.56
26.57
26.58
26.59
26.60
26.61
26.62
26.63
26.64
26.65
26.66
26.67
26.68
26.69
26.70
26.71
26.72
26.73
26.74
26.75
26.76
26.77
26.78
26.79
26.80
26.81
26.82
26.83
26.84
26.85
26.86
26.87
26.88
#: Reassemble another type shim or check the backlash after assembling A shim.
A
#
B
C
D
A + A
A + B
B + B
B + C
C + C
C + D "
X mm
Y mm
u
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
SA-151
2101 Author
: Date
:
2004 LAND CRUISER (RM1071U)

F05260
"
X in.
1.8129
1.0413
Y in.
#: Reassemble another type shim or check the backlash after assembling A shim.
A
#
B
C
D
A + A
A + B
B + B
B + C
C + C
C + D
1.8133 1.8137 1.8141 1.8145 1.8149 1.8153 1.8157 1.8161 1.8165 1.8169 1.8173 1.8181 1.81881.8177 1.8185 1.8192 1.8196
1.0417
1.0421
1.0425
1.0429
1.0433
1.0436
1.0440
1.0444
1.0448
1.0452
1.0456
1.0460
1.0496
1.0499
1.0503
1.0507
1.0515
1.0519
1.0523
1.0527
1.0531
1.0535
1.0539
1.0543
1.0547
1.0551
1.0555 1.0464
1.0468
1.0472
1.0476
1.0480
1.0484
1.0488
1.0492
1.0559
1.0562
1.0566
1.0570
1.0574
1.0578
1.0582 1.0511
u
SA-152
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2102 Author
: Date
:
2004 LAND CRUISER (RM1071U)

W01877
W01878
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
SA-153
2103 Author
: Date
:
2004 LAND CRUISER (RM1071U)
Adjust shim thickness:
MarkThickness mm (in.)MarkThickness mm (in.)
A0.20 (0.0079)C0.30 (0.0118)
B0.25 (0.0098)D0.35 (0.0138)
2. CHECK SIDE GEAR BACKLASH
(a) Install the thrust washers, clutch plates and adjusting
shim to side gear.
HINT:
Install the adjusting shim with its surface having no oil groove
facing to the differential case side.
(b) Install the side gear to the differential case.
(c) Install the 4 pinion gears and thrust washers to the spider.
(d) Align the spring retainer holes with the straight pins and
install the retainer.
(e) Install the spider to the differential case.
HINT:
Install the spider to the differential case tightly and do not move
the spring retainer.
(f) Using a dial indicator, measure the side gear backlash
while holding the side gear and spider.
Backlash: 0.02 - 0.15 mm (0.0008 - 0.0059 in.)
HINT:

Measure at all 4 locations.

Measure the backlash at the RH and LH differential
cases.
If the backlash is not within the specified value, select the ad-
justing shim.
3. ASSEMBLE DIFFERENTIAL CASE
(a) Reinstall the spider to the LH differential case.
HINT:
Install the spider to the LH differential case tightly and do not
move the spring retainer.
(b) Install the compression spring and RH spring retainer.
(c) Install the RH side gear.
(d) Align the matchmarks and assemble the RH and LH dif-
ferential cases.

F05192
SST
F05193
SST
SST
SA1143
Boiling Water
F05204
Matchmarks
SA-154
- SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER (w/ LSD)
2104 Author
: Date
:
2004 LAND CRUISER (RM1071U)
HINT:

Be careful not to drop the side gear.

Check the pinion and side gear alignment.
(e) Tighten the 8 bolts uniformly, a little at a time.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
4. INSTALL SIDE BEARING
(a) Using SST and a press, install the RH side bearing on the
differential case.
SST 09710-30050, 09950-70010 (09951-07100)
(b) Using SST and a press, install the LH side bearing on the
differential case.
SST 09710- 30050, 09950- 60010 (09951- 00480),
09950-70010 (09951-07100)
5. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the threads of the bolts and differential case with
the white gasoline.
(b) Clean the contact surfaces of the differential case and
ring gear.
(c) Heat the ring gear to about 100 °C (212 °F) in boiling wa-
ter.
(d) Carefully take the ring gear out of the boiling water.
(e) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(f) Align the matchmarks on the ring gear and differential
case.
(g) Temporarily install the 12 set bolts.
(h) After the ring gear has cooled down enough, torque the
12 set bolts to which thread lock has been applied.
Thread lock:
Part No. 08833-00100, THREE BOND 1360K
or equivalent
Torque: 137 N´m (1,400 kgf´cm, 101 ft´lbf)