TOYOTA LAND CRUISER 1998 Factory Repair Manual
Manufacturer: TOYOTA, Model Year: 1998, Model line: LAND CRUISER, Model: TOYOTA LAND CRUISER 1998Pages: 3115, PDF Size: 54.88 MB
Page 3101 of 3115
TF0986
TF0857
D04308
Socket Wrench
D02671
TF0862
SST
- TRANSFERTRANSFER ASSEMBLY
TR-1 1
1899 Author: Date:
2004 LAND CRUISER (RM1071U)
17. REMOVE IDLER GEAR ASSEMBLY WITH CENTER
DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND
SHIFT FORK NO. 1 SHAFT FROM FRONT CASE
18. SEPARATE SHIFT FORK NO. 1 AND SHIFT FORK NO.
1 SHAFT
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Separate the shift fork No. 1 and shift fork No. 1 shaft.
19. REMOVE SHIFT OUTER LEVER AND INNER LEVER
(a) Remove the nut and washer from the shift outer lever.
(b) Using a brass bar, hammer and socket wrench, tap out
the lever lock pin.
(c) Remove the shift outer lever, washer and inner lever from
the front case.
20. IF NECESSARY, REPLACE INNER SHIFT LEVER OIL
SEAL
(a) Using a screwdriver, pry out the oil seal from the front
case.
(b) Apply MP grease to the lip of a new oil seal.
(c) Using SST and a hammer, drive in a new oil seal.
SST 09950- 60010 (09951- 00270), 09950- 70010
(09951-07150)
Page 3102 of 3115
TF0864
SST
SST
D02672
D02770
SST
TF0867
TR-12
- TRANSFERTRANSFER ASSEMBLY
1900 Author: Date:
2004 LAND CRUISER (RM1071U)
21. IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL
(a) Using SST and a hammer, drive out the oil seal.
SST 09316-6001 1 (09316-00011)
(b) Apply MP grease to the lip of a new oil seal.
(c) Using SST and a hammer, drive in a new oil seal.
SST 09316-6001 1 (09316-00011, 09316-00031)
22. REMOVE OIL RECEIVER FROM FRONT CASE
Remove the bolt and oil receiver.
23. REMOVE 2 BEARING RACES FROM FRONT CASE
(a) Using SST, remove the bearing race (for the idler gear).
SST 09950- 40011 (09951- 04020, 09952- 04010,
09953- 04030, 09954- 04010, 09955- 04061,
09957-04010), 09950-60010 (09951-00320)
(b) Using a brass bar and hammer, remove the bearing race
(for the output shaft).
Page 3103 of 3115
TR06Y-01
D02673
D02662
SST
D02661
SST
D02672
D04309Socket Wrench
- TRANSFERTRANSFER ASSEMBLY
TR-13
1901 Author: Date:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
1. INSPECT SHIFT FORK NO. 2 AND CLUTCH SLEEVE
CLEARANCE
Using a feeler gauge, measure the clearance between the shift
fork No. 2 and clutch sleeve.
Standard clearance:
0.10 - 0.40 mm (0.0039 - 0.0157 in.)
Maximum clearance:
0.40 mm (0.0157 in.)
2. INSTALL THE BEARING RACE (FOR THE OUTPUT
SHAFT)
Using SST and a press, install the bearing race.
SST 09316-6001 1 (09316-00011, 09316-00031),
09950-60020 (09951-00890)
3. INSTALL THE BEARING RACE (FOR THE IDLER
GEAR)
Using SST and a press, install the bearing race.
SST 09316-6001 1 (09316-00011, 09316-00031),
09950-60020 (09951-00790)
4. INSTALL OIL RECEIVER TO FRONT CASE
Install the oil receiver and bolt.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
5. INSTALL SHIFT OUTER LEVER AND INNER LEVER
(a) Install the shift inner lever, washer and outer lever to the
front case.
(b) Using a pin punch, hammer and socket wrench, tap in the
lever lock pin.
(c) Install the washer and nut to the shift outer lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
Page 3104 of 3115
TF0857
TF0986
D02756
FIPG3 mm (0.12 in.)
D02864A
D02669
TR-14
- TRANSFERTRANSFER ASSEMBLY
1902 Author: Date:
2004 LAND CRUISER (RM1071U)
6. ASSEMBLE SHIFT FORK NO. 1 AND SHIFT FORK NO.
1 SHAFT
(a) Assemble the shift fork No. 1 and shift fork No. 1 shaft.
(b) Using a pin punch and hammer, drive in the slotted spring
pin.
7. INSTALL IDLER GEAR ASSEMBLY WITH CENTER
DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND
SHIFT FORK NO. 1 SHAFT TO FRONT CASE
NOTICE:
Set the shift inner lever into the fork head part of the shift
fork No. 1 securely.
8. INSTALL INPUT SHAFT ASSEMBLY
9. INSTALL 2 BEARING RACES TO REAR CASE
10. ASSEMBLY FRONT CASE AND REAR CASE
(a) Apply FIPG to the front case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Assemble the front case and rear case.
(c) Apply liquid sealer to the ºAº bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Install the 8 bolts.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
11. ASSEMBLE FRONT CASE AND REAR CASE
Using a snap ring expander, install the snap ring to the rear
case.
Page 3105 of 3115
D02754FIPG5 mm (0.20 in.)
D02863
D02667
Z18975
A
Z18976
B
- TRANSFERTRANSFER ASSEMBLY
TR-15
1903 Author: Date:
2004 LAND CRUISER (RM1071U)
12. INSTALL CASE COVER
(a) Apply FIPG to the rear case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Install the case cover.
(c) Apply liquid sealer to the bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Install the 5 bolts.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
13. INSTALL OIL STRAINER TO REAR CASE
Install the oil strainer and 2 bolts.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
14. SELECT ADJUSTING SHIM FOR IDLER GEAR REAR
TAPER ROLLER BEARING
(a) Using vernier calipers, measure dimension ºAº.
(b) Lightly hole down the bearing outer race in the thrust
direction to eliminate any looseness before making the
measurement.
(c) Using a steel straight edge and feeler gauge, measure
the clearance of dimension ºBº.
(d) Calculate the required thickness of the adjusting shim.
Thickness: Dimension ºAº + Dimension ºBº + [0.022
- 0.049 mm, (0.0009 - 0.0019 in.)]
Page 3106 of 3115
TF1063
C
TF1064
F
E
D
TF1065
F
GH TR-16
- TRANSFERTRANSFER ASSEMBLY
1904 Author: Date:
2004 LAND CRUISER (RM1071U)
(e) From the following table, select a shim so that its thick-
ness is within the range of the calculation.
MarkThickness mm (in.)MarkThickness mm (in.)
20.30 (0.0118)83.20 (0.1260)
30.45 (0.0177)93.40 (0.1339)
42.40 (0.0945)103.60 (0.1417)
52.60 (0.1024)113.80 (0.1496)
62.80 (0.1102)124.00 (0.1575)
73.00 (0.1181)130.55 (0.0216)
15. SELECT ADJUSTING SHIM FOR OUTPUT SHAFT TA-
PER ROLLER BEARING
(a) Using a steel straight edge and feeler gauge, measure
the clearance of dimension ºCº.
(b) Lightly hold down the bearing outer race in the thrust
direction to eliminate any looseness before making the
measurement.
(c) Using a steel straight edge and vernier calipers with depth
gauge, measure dimension ºDº.
(d) Dimension ºDº is the straight edge thickness (Dimension
ºFº) subtracted from dimension ºEº in the illustration to the
left.
Dimension ºDº: Dimension ºEº - Dimension ºFº
(e) Using a steel straight edge and vernier calipers with depth
gauge, measure dimension ºGº.
(f) Dimension ºGº is the straight edge thickness (Dimension
ºFº) subtracted from Dimension ºHº.
Dimension ºGº: Dimension ºHº - Dimension ºFº
(g) Calculate the required thickness of the adjusting shim.
Thickness: Dimension ºGº - (Dimension ºDº - Di-
mension ºCº) + [0.014 ~ 0.039 mm, (0.0006 ~ 0.0015
in.)]
(h) From the following table, select a shim so that its thick-
ness is within the range of the calculation.
MarkThickness mm (in.)MarkThickness mm (in.)
B0.30 (0.0118)H1.80 (0.0709)
C0.45 (0.0177)J2.00 (0.0787)
D1.00 (0.0394)K2.20 (0.0866)
E1.20 (0.0472)L2.40 (0.0945)
F1.40 (0.0551)M2.60 (0.1024)
G1.60 (0.0630)N0.55 (0.0216)
Page 3107 of 3115
D01995
FIPG 3 mm (0.12 in.)
D02861
Q00541
Front
D01991
FIPG
4 mm (0.16 in.)
D02860
- TRANSFERTRANSFER ASSEMBLY
TR-17
1905 Author: Date:
2004 LAND CRUISER (RM1071U)
16. INSTALL REAR EXTENSION HOUSING
(a) Apply FIPG to the rear extension housing.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Install the rear extension housing and 9 bolts.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
17. ASSEMBLE SHIFT FORK NO. 2 SHAFT AND SHIFT
FORK NO. 2
(a) Install the shift fork No. 2 to the shift fork No. 2 shaft.
(b) Install the 3 snap rings to the shift fork No. 2 shaft.
18. INSTALL CLUTCH SLEEVE WITH SHIFT FORK NO. 2
SHAFT AND SHIFT FORK NO. 2
HINT:
Make sure to install the clutch sleeve in the correct direction.
19. INSTALL FRONT EXTENSION HOUSING
(a) Apply FIPG to the front extension housing.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Install the front extension housing and 6 bolts.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
HINT:
Set the clutch sleeve in differential lock condition.
20. INSTALL TRANSFER INDICATOR SWITCH
Install the 3 transfer indicator switches with 3 new gaskets.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
Page 3108 of 3115
Q07105
D02862
D02666FIPG4 mm (0.16 in.)
Q04610
D02690
TR-18
- TRANSFERTRANSFER ASSEMBLY
1906 Author: Date:
2004 LAND CRUISER (RM1071U)
21. INSTALL BALL, SPRING AND SCREW
(a) Install the ball and spring.
(b) Apply liquid sealer to the screw plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(c) Using a torx socket wrench (T40), install the screw plug.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
22. INSTALL OUTPUT GEAR TO FRONT CASE
HINT:
Apply gear oil to the output gear.
NOTICE:
Do not turn the output gear.
23. INSTALL MOTOR ACTUATOR
(a) Apply FIPG to the motor actuator.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
HINT:
Set the motor actuator in differential lock condition.
(b) Install the motor actuator and 4 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
24. INSTALL SPEED SENSOR DRIVE GEAR
Install the driven gear and bolt.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
25. INSTALL BREATHER HOSE
Page 3109 of 3115
TR064-02
- TRANSFERTRANSFER SYSTEM
TR-1
1889 Author: Date:
2004 LAND CRUISER (RM1071U)
TRANSFER SYSTEM
PRECAUTION
When working with FIPG material, you must observe the following.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non-residue solvent.
Apply FIPG in an approx. 1.2 mm (0.047 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.
Page 3110 of 3115
TR066-02
D02887
Transfer Indicator Switch
Connector
(Neutral Switch)
Transfer Indicator
Switch Connector
(Center Diff. Lock)Transfer Indicator Switch Connector
(Low Switch)
Motor Actuator Connector
No. 1 Vehicle Speed Sensor Connector Rear Propeller Shaft
Breather Hose
Transfer
Ground Cable
106 (1,080, 78)
69 (700, 51)
69 (700, 51)
Clip
Plate Washer
Wave Washer
Transfer Shift Lever Rod
AssemblyBushing
69 (700, 51)
69 (700, 51)
Transfer Case Protector
: Specified torque
N´m (kgf´cm, ft´lbf)Front Propeller ShaftCrossmember
50 (510, 37)
50 (510, 37)
74 (750, 54)
50 (510, 37)
28 (290, 21)
106 (1,080, 78)
106 (1,080, 78)
106 (1,080, 78)
80 (820, 59)
80 (820, 59)
80 (820, 59)
80 (820, 59)
- TRANSFERTRANSFER UNIT
TR-3
1891 Author: Date:
2004 LAND CRUISER (RM1071U)
TRANSFER UNIT
COMPONENTS