TOYOTA LAND CRUISER 1998 Factory Repair Manual

- SUSPENSION AND AXLETIRE AND WHEEL
SA-5
1955 Author
: Date
:
2004 LAND CRUISER (RM1071U)
4. CHECK FRONT SUSPENSION FOR LOOSENESS
5. CHECK STEERING LINKAGE FOR LOOSENESS
6. CHECK BALL JOINT FOR LOOSENESS
7. CHECK SHOCK ABSORBER WORKS PROPERLY

Check that oil leaks

Check the mounting bushings for wear

Bounce front and rear of the vehicle

SA140-09
- SUSPENSION AND AXLETROUBLESHOOTING
SA-1
1951 Author
: Date
:
2004 LAND CRUISER (RM1071U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
(w/ Differential locking system):

Check that the transfer shift lever is shifted to the L position.

When switching differential Free e Lock, the indicator light will blink if the gears of the differen-
tial lock sleeve are not meshed. If this occurs, when the tires are rotated to apply differential
power to the differential, the differential locks and the indicator light lights up.
SymptomSuspect AreaSee page
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)-
SA-65
SA-171
SA-62
SA-174
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)SA-4
SA-80
SA-184
SA-62
SA-174
Front wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Ball joint (Worn)
6. Hub bearing (Loosen or worn)
7. Steering linkage (Loosen or worn)
8. Steering gear (Out of adjustment or broken)SA-4
SA-4
SA-62
SA-6
SA-71
SA-76
SA-1 1
-
SR-48
Abnormal tire wear
1. Tire (Improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)SA-4
SA-6
SA-62
SA-174
-
Noise in front differential
1. Oil level (Low or wrong grade)
2. Excessive backlash between pinion and ring gear
3. Ring, pinion or side gears (Worn or chipped)
4. Pinion shaft bearing (Worn)
5. Side bearing (Worn)SA-35
SA-40
SA-40
SA-40
SA-40
Oil leak from front differential
1. Oil level (Too high or wrong grade)
2. Front differential rear oil seal (Worn or damaged)
3. Side gear oil seal (Worn or damaged)
4. Companion flange (Loosen or damaged)
5. Side gear shaft (Damaged)SA-35
SA-40
SA-40
SA-40
SA-40

SA-2
- SUSPENSION AND AXLETROUBLESHOOTING
1952 Author
: Date
:
2004 LAND CRUISER (RM1071U) Noise in rear axle
1. Oil level (Low or wrong grade)
2. Excessive backlash between pinion and ring gear
3. Ring, pinion or side gears (Worn or chipped)
4. Pinion shaft bearing (Worn)
5. Axle shaft bearing (Worn)SA-95
SA-102
SA-121
SA-143
SA-102
SA-121
SA-143
SA-102
SA-121
SA-143
SA-83
Oil leak from rear axle1. Oil seal (Worn or damaged)
2. Rear axle housing (Cracked)SA-83
-
Oil leak from rear differential
1. Oil level (Too high or wrong grade)
2. Rear differential front oil seal (Worn or damaged)
3. Companion flange (Loosen or damaged)SA-95
SA-95
SA-102
SA-121
SA-143
Diff. lock Indicator lights do not light up
1. Fusible link (Blown)
2. GAUGE fuse (Blown)
3. Bulb (Burned out)
4. Wiring or ground (Faulty)-
-
-
-
Diff. lock Indicator lights do not light up
(Diff. lock control switch RR position)
1. Diff. fuse (Blown)
2. Diff. lock control switch (Faulty)
3. Diff. lock ECU (Faulty)
4. Wiring or ground (Faulty)-
SA-163
SA-163
-
Differential lock does not operate
1. Diff. lock control switch (Faulty)
2. Diff. lock actuator (Faulty)
3. Diff. lock ECU (Faulty)
4. Differential carrier (Faulty)
5. Wiring or ground (Faulty)SA-163
SA-163
SA-163
-
-
After differential lock, lock is not released
When vehicle speed is at 8 km/h (5 mph) or more1. Speed sensor (Faulty)
2. Diff. lock ECU (Faulty)
3. Wiring or ground (Faulty)SA-163
SA-163
-

SA28F-03
START
Preliminary Check
Tire pressure
Vehicle height
Brake dragging ROAD TEST
Does the vehicle lead/pull?
Cross switch front tire & wheel
assemblies (left & right).
Does the vehicle lead/pull in
same direction as before?
Check front wheel alignment.
Is it within specification?
Adjust front wheel alignment.Reverse the front left side
tire and rebalance it.
Does the vehicle
lead/pull to the left?
COMPLETE
Are the tires uni-directional type?
Choose the position of front tire & wheel
assemblies where there is least amount of pull.
Increase left front camber and decrease
right front camber until lead/pull is eliminated.Increase right front camber and decrease
left front camber until lead/pull is eliminated.
NO
YES
YES
NO
YES
YES
NO
YES
NO COMPLETE
NONOYES NOIs there steering
off center?
Adjust front tie rods.
NO
YES
Is the lead/pull stronger
than before?
YES
NOTICE : Do not exceed 1° of cross camber.
Do not exceed adjustment range.
Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed
of 35mph. Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in
a straight line for 100 meters at a constant speed of 35mph without holding the steering wheel.
(1) The vehicle can keep straight but the steering wheel has some angle.
STEERING OFF CENTER (See page SR-10)
(2) The vehicle cannot keep straight.
STEERING PULL
YES NO
YES ROAD TEST
Does the vehicle still lead/pull?
NO ROAD TEST
Does the vehicle still lead/pull? ROAD TEST
Does the vehicle still lead/pull?
ROAD TEST
Does the vehicle still lead/pull?NO
Contact your local retail tire distributor.YES
*
*
- SUSPENSION AND AXLETROUBLESHOOTING
SA-3
1953 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REPAIR PROCEDURES
HINT:
This is a flow chart for vehicle pull.

TR06J-02
D04344
Front Drive
Gear Piece

Snap RingFront Taper
Roller BearingNeedle Roller BearingClutch Hub High Speed Output
Gear Bushing High Speed
Output Gear
Rear Taper
Roller Bearing
x12
Differential
Rear Case
Pinion ShaftRear Side
Gear
: Specified torqueThrust Washer
Front Side Gear
N´m (kgf´cm, ft´lbf)Straight Pin
Low GearStraight PinHigh and Low
Clutch Sleeve
Thrust Washer
Thrust Washer Thrust Washer

Non-reusable partPinion Gear
Differential
Front Case
See page TR-31
Pinion Gear
- TRANSFERCENTER DIFFERENTIAL
TR-27
1915 Author
: Date
:
2004 LAND CRUISER (RM1071U)
CENTER DIFFERENTIAL
COMPONENTS

TR06K-02
TF0900
TF0944
Q07101
SST
Q07102
SST
D02679
TR-28
- TRANSFERCENTER DIFFERENTIAL
1916 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND
THRUST CLEARANCE
(a) Using a feeler gauge, measure the high speed output
gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)
(b) Using a dial indicator, measure the high speed output
gear radial clearance.
Standard clearance:
0.035 - 0.091 mm (0.00138 - 0.00358 in.)
Maximum clearance:
0.091 mm (0.00358 in.)
2. REMOVE FRONT DRIVE GEAR PIECE
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the front drive gear piece.
SST 09950-00020, 09950-60010 (09951-00320)
NOTICE:
Be careful not to drop the center differential assembly.
3. REMOVE FRONT TAPER ROLLER BEARING
Using SST and a press, remove the front taper roller bearing.
SST 09950-00020
NOTICE:
Set the claw of SST to the bearing inner race securely.
4. REMOVE HIGH SPEED OUTPUT GEAR
5. REMOVE 2 NEEDLE ROLLER BEARINGS

D02680
Q07103
SST
Q07113
SST
D02681
D02682
- TRANSFERCENTER DIFFERENTIAL
TR-29
1917 Author
: Date
:
2004 LAND CRUISER (RM1071U)
6. REMOVE HIGH AND LOW CLUTCH SLEEVE
7. REMOVE HIGH SPEED OUTPUT GEAR BUSHING
AND CLUTCH HUB
(a) Using SST, remove the high speed output gear bushing
and clutch hub.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00320)
(b) Using a magnetic finger, remove the straight pin from the
differential front case.
8. REMOVE REAR TAPER ROLLER BEARING
Using SST and a press, remove the rear taper roller bearing.
SST 09950-00020, 09950-60010 (09951-00320)
NOTICE:
Set the claw of SST to the bearing inner race securely.
9. REMOVE DIFFERENTIAL REAR CASE
Remove the 12 bolts and differential rear case.
10. REMOVE THRUST WASHER AND REAR SIDE GEAR

D02683
D02684
D02685
D02686
TR-30
- TRANSFERCENTER DIFFERENTIAL
1918 Author
: Date
:
2004 LAND CRUISER (RM1071U)
11. REMOVE PINION SHAFT, 2 PINION GEARS AND 2
THRUST WASHERS
(a) Remove the straight pin from the pinion shaft.
(b) Remove the pinion shaft, 2 pinion gears and thrust wash-
ers.
(c) Remove the front side gear and thrust washer.
12. REMOVE LOW GEAR
Using a plastic hammer, tap and remove the low gear.
NOTICE:
Be careful not to damage the low gear.

TR06L-02
D02687
TF1012
TF0913
- TRANSFERCENTER DIFFERENTIAL
TR-31
1919 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL LOW GEAR
(a) Clean the contact surface of the differential case.
(b) Heat the low gear in boiling water.
(c) Carefully remove the low gear from the water.
(d) After the moisture on the low gear has completely evapo-
rated, quickly install the low gear to the differential case.
2. INSTALL THRUST WASHER AND FRONT SIDE GEAR
3. INSTALL PINION SHAFT, 2 PINION GEARS AND 2
THRUST WASHERS
(a) Install the pinion shaft, 2 pinion gears and thrust washers
to the differential front case.

TF0917
TF0920
Q00534
SST
Q00547
SST
SST
TR-32
- TRANSFERCENTER DIFFERENTIAL
1920 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(b) Using a dial indicator, measure the front case backlash.
HINT:
Push the pinion shaft.
Maximum backlash: 0.05 mm (0.0020 in.)
If the backlash is not within the specification, replace the thrust
washer with one of the correct size and reinstall the thrust wash-
er.
Thickness mm (in.)Thickness mm (in.)
1.70 (0.0669)2.45 (0.0965)
1.85 (0.0728)2.60 (0.1024)
2.00 (0.0787)2.75 (0.1083)
2.15 (0.0846)2.90 (0.1142)
2.30 (0.0906)3.05 (0.1201)
(c) In the same way, measure the rear case backlash.
4. INSTALL STRAIGHT PIN TO PINION SHAFT
5. INSTALL REAR SIDE GEAR AND THRUST WASHER
6. INSTALL DIFFERENTIAL REAR CASE
(a) Install the differential rear case and 12 set bolts.
Torque: 88 N´m (900 kgf´cm, 65 ft´lbf)
(b) Turn the pinion gear.
(c) Loosen the 12 rear case set bolts.
(d) Torque the 12 rear case set bolts.
Torque: 98 N´m (1,000 kgf´cm, 72 ft´lbf)
7. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing.
SST 09316-12010
8. INSTALL CLUTCH HUB
Using SST and a press, install the clutch hub.
SST 09316-12010, 09316-60011 (09316-00011)