TOYOTA LAND CRUISER 1998 Factory Repair Manual

TR06H-02
D02676
D02677
- TRANSFERIDLER GEAR
TR-25
1913 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSPECTION
1. INSPECT IDLER GEAR
Using a micrometer, measure the idler gear diameter.
Standard diameter:
38.48 - 38.50 mm (1.5149 - 1.5157 in.)
Maximum diameter:
38.50 mm (1.5157 in.)
2. INSPECT IDLER LOW GEAR
Using a cylinder gauge, measure the idler low gear diameter.
Standard diameter:
45.52 - 45.54 mm (1.7922 - 1.7930 in.)
Maximum diameter:
45.54 mm (1.7930 in.)

TR06I-02
TF0893
SST
Q00538
D02678
TF0896
SST TR-26
- TRANSFERIDLER GEAR
1914 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL FRONT TAPER ROLLER BEARING
Using SST and a press, install the front taper roller bearing.
SST 09316-6001 1 (09316-00011, 09316-00031)
2. INSTALL HIGH AND LOW CLUTCH SLEEVE
HINT:
Make sure to install the high and low clutch sleeve in the correct
direction.
3. INSTALL NEEDLE ROLLER BEARING AND IDLER
LOW GEAR TO IDLER GEAR
(a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing and idler low gear.
4. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing.
SST 09316-6001 1 (09316-00011, 09316-00071)
5. INSPECT IDLER LOW GEAR RADIAL AND THRUST
CLEARANCE (See page TR-25)

TR06C-02
D02654

Snap Ring
Front Ball BearingInput Shaft
Rear Ball Bearing

Non-reusable part

Snap Ring
- TRANSFERINPUT SHAFT
TR-19
1907 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INPUT SHAFT
COMPONENTS

D02691
TR06D-03
D02853
Socket Wrench
D02655
SST
TR-20
- TRANSFERINPUT SHAFT
1908 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. REMOVE REAR BALL BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a socket wrench and press, remove the rear ball
bearing.
2. REMOVE FRONT BALL BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST, remove the front ball bearing.
SST 09950- 40011 (09951- 04020, 09952- 04010,
09953- 04030, 09954- 04010, 09955- 04011,
09957- 04010, 09958- 04011), 09950- 60010
(09951-00400)

TR06E-02
D02656
SST
D02657
D02658
SST
D02659
- TRANSFERINPUT SHAFT
TR-21
1909 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL FRONT BALL BEARING
(a) Using SST and a press, install a new front ball bearing.
SST 09316-6001 1 (09316-00011)
(b) Select a snap ring that will allow the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.90 (0.1141)D3.05 (0.1201)
B2.95 (0.1161)E3.10 (0.1220)
C3.00 (0.1181)F3.15 (0.1240)
(c) Using a snap ring expander, install a new snap ring.
2. INSTALL REAR BALL BEARING
(a) Using SST and a press, install the rear ball bearing.
SST 09316-6001 1 (09316-00011, 09316-00031)
(b) Select a snap ring that will allow the minimum axial play.
MarkThickness mm (in.)
A2.00 (0.0787)
B2.10 (0.0827)
C2.20 (0.0866)
D2.30 (0.0906)
E2.40 (0.0945)
(c) Using a snap ring expander, install a new snap ring.

D02866
ON
OFF
TR06V-02
D02867
L
NH
Z15367
Relay side:
- TRANSFERMOTOR SHIFT CONTROL SYSTEM
TR-49
1937 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSPECTION
1. INSPECT SWITCH POSITION
(a) Start the engine, and shift the transfer shift lever to the ºHº
position.
(b) Check that the center diff. indicator light comes on when
the the switch is in ºONº position. Check that the light goes
off when the switch is in ºOFFº position.
2. INSPECT SHIFT LEVER POSITION
(a) Start the engine, and turn the center diff. lock switch to
OFF.
(b) Check that the center diff. indicator light comes on when
the transfer shift lever is shifted to the ºLº position. Check
that the light goes off when the lever is shifted to the ºNº
or ºHº position.
3. INSPECT CENTER DIFF. LOCK CONTROL RELAY
(a) Check that continuity exists between each terminal, as
shown in the chart.
Tester connected terminal numberSpecified condition
1 - 2Continuity
2 - 4Continuity
6 - 7*
*: There is a diode between the terminals 6 and 7.
If no continuity exists, check that continuity exists when chang-
ing the position of
probe for the position of negative  probe
of tester.
(b) Apply battery positive voltage between each terminal and
check that continuity exists between each terminal, as
shown in the chart.
Battery voltage
applied terminalTester connected terminal
numberSpecified condition
6 (+) - 5 (-)1 - 3
1 - 2Continuity
No continuity
7 (+) - 2 (-)9 - 10No continuity
9 (+) - 10 (-)3 - 4
2 - 4Continuity
No continuity
If continuity is not as specified, replace the relay.

D02869
12
4
3 5
1 4
3 5 2 1
1 2 3 4
52
3 4
5
Free " Lock
Lock " Free
D04311
Heater main relay:
1 42
5
3
1 2
3
4
5
*
*:Relay housing
metallic parts
D02663
Motor actuator side: TR-50
- TRANSFERMOTOR SHIFT CONTROL SYSTEM
1938 Author
: Date
:
2004 LAND CRUISER (RM1071U)
4. INSPECT ACTUATOR OPERATION
(a) Raise up the front wheels, place the stopper under the
rear wheels to block them, and pull up the parking brake.
(b) Disconnect the connector of the actuator and connect it
to the relay using wire.
(c) Check that the front propeller shaft can be rotated by
hand.
Inspection ItemStandard
Center Diff.
Free " LockFront propeller shaft cannot be rotated.
Center Diff.
Lock " FreeFront propeller shaft can be rotated.
HINT:
When inspecting the operation described above, use a heater
main relay.
NOTICE:
Connect the terminals being careful not to touch the neigh-
boring terminals or metallic parts of relay housing.
5. INSPECT MOTOR ACTUATOR (MOTOR)
(a) Remove the motor actuator (See page TR-8).
(b) Measure the resistance between the terminals 1 and 5.
Standard resistance: 0.3 - 100 W
(c) Measure the resistance between the terminals 1 or 5 and
body ground.
Standard resistance: More than 0.5 MW
If the resistance value is not as specified, replace the motor ac-
tuator.

D02877
123
D02665
ON-OFF27±0.82mm Ball
- TRANSFERMOTOR SHIFT CONTROL SYSTEM
TR-51
1939 Author
: Date
:
2004 LAND CRUISER (RM1071U)
6. INSPECT CENTER DIFF. LOCK SWITCH CONTINUITY
(a) Remove the center diff. lock switch (See page AC-102).
(b) Inspect the continuity between each terminal.
Center diff. lock switch
conditionTester connected terminal
numberSpecified condition
ON
1 - 2
1 - 3
2 - 3No continuity
No continuity
Continuity
OFF
1 - 2
1 - 3
2 - 3Continuity
No continuity
No continuity
7. INSPECT TRANSFER INDICATOR SWITCH CONTINU-
ITY
(a) Remove the 3 transfer indicator switches (See page
TR-8).
(b) Check that continuity exists between terminals 1 and 2
when pushing the ball at the tip of the switch.

TR06U-02
D03520
Center Diff. Lock Switch
Center Diff. Lock Indicater Light
Transfer Indicator Switch
(Center Diff. Lock)
Motor Actuator
Transfer Indicator Switch
(Low Switch)Center Diff. Lock
Control Relay
Transfer Indicator Switch
(Neutral Switch)
TR-48
- TRANSFERMOTOR SHIFT CONTROL SYSTEM
1936 Author
: Date
:
2004 LAND CRUISER (RM1071U)
MOTOR SHIFT CONTROL SYSTEM
LOCATION

TR06P-02
D04346
Ball
Bearing Dust Deflector
Seal RingRear Output Shaft

Screw Plug
Ball
Rear Extension Housing Driven Rotor Speed Sensor Drive Gear
Drive Rotor Oil Pump CoverSpring Valve Seat
4.9 (50, 43 in.´lbf)
29 (300, 22)
 Oil Seal
 Snap Ring Snap Ring
Oil Pump
Drive ShaftOil Pump Plate
N´m (kgf´cm, ft´lbf)
: Specified torque
 Non-reusable part

Precoated part
4.9 (50, 43 in.´lbf)
TR-40
- TRANSFERREAR EXTENSION HOUSING
1928 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REAR EXTENSION HOUSING
COMPONENTS