Toyota land cruiser 1998 2007 transfer hệ thống chuyển cầu trên xe land cruiser đời 1998 2007

HỆ THỐNG CHUYỂN CẦU TRÊN XE LAND CRUISER ĐỜI 1998-2007

D04344

Front DriveGear Piece

Snap Ring

Front TaperRoller Bearing

Needle Roller Bearing

Clutch Hub

High Speed OutputGear BushingHigh Speed

Output Gear

Rear TaperRoller Bearing

x12

Differential Rear CasePinion Shaft

Rear Side Gear

Non-reusable part

Pinion Gear

DifferentialFront Case

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

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 bushingand clutch hub

SST 09950- 00020, 09950- 00030, 09950- 60010

(09951-00320)(b) Using a magnetic finger, remove the straight pin from thedifferential 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

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 ers

wash-(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.

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 rated, quickly install the low gear to the differential case

evapo-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

(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 thrustwasher with one of the correct size and reinstall the thrust wash-er

Thickness mm (in.) Thickness mm (in.)

(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)

9 INSTALL HIGH SPEED OUTPUT GEAR BUSHING

(a) Apply MP grease to the straight pin

(b) Install the straight pin, as shown

(c) Using SST and a press, install the high speed output gearbushing

(a) Apply gear oil to the needle roller bearing

(b) Install the needle roller bearing and high speed outputgear

12 INSTALL FRONT TAPER ROLLER BEARING

Using SST and a press, install the front taper roller bearing.SST 09316-12010, 09316-60011 (09316-00011)

13 INSTALL FRONT DRIVE GEAR PIECE

Using SST and a press, install the front drive gear piece.SST 09316-12010, 09316-60011 (09316-00011)

14 INSTALL SNAP RING

(a) Select a snap ring that will allow the minimum axial play

Mark Thickness mm (in.) Mark Thickness mm (in.)

-(b) Using a snap ring expander, install a new snap ring

15 INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE (See page TR-28 )

1 REMOVE DRIVE CLUTCH HUB

(a) Using a snap ring expander, remove the snap ring.(b) Using SST, remove the drive clutch hub

SST 09950- 40011 (09951- 04020, 09952- 04010,

09953- 04030, 09954- 04020, 09955- 04021,09957-04010, 09958-04011)

2 REMOVE FRONT OUTPUT SHAFT

Using a plastic hammer, drive out the front output shaft

3 REMOVE DUST DEFLECTOR

(a) Using SST, remove the dust deflector

SST 09950- 40011 (09951- 04020, 09952- 04010,

09953- 04030, 09954- 04010, 09955- 04051,09957-04010, 09958-04011)

(b) Using a screwdriver and hammer, tap the dust deflectorand remove it from the extension housing

4 REMOVE OIL SEAL

Using a screwdriver, pry out the oil seal from the front extensionhousing

5 REMOVE BALL BEARING

(a) Using a screwdriver, remove the snap ring

(b) Using SST and a press, remove the ball bearing.SST 09316-6001 1 (09316-00011, 09316-00071)

1 INSTALL DUST DEFLECTOR

(a) Using a plastic hammer, install a new dust deflector to thefront extension housing

(b) Using SST and a press, install a new dust deflector to thefront output shaft

SST 09316-2001 1, 09316-60011 (09316-00011)

2 INSTALL BALL BEARING

(a) Using SST and a press, install the ball bearing to the frontextension housing

SST 09316-6001 1 (09316-00011, 09316-00031)

(b) Select a snap ring that will allow the minimum axial play

(c) Using a screwdriver, install a new snap ring

3 INSTALL OIL SEAL

(a) Apply MP grease to the lip of a new oil seal

(b) Using SST and a hammer, drive in a new oil seal to thefront extension housing

SST 09316-6001 1 (09316-00011, 09316-00061)

(b) Select a snap ring that will allow the minimum axial play.

Z15264

Front Taper Roller

High and Low Clutch Sleeve

Needle Roller Bearing

Idler Low Gear

Rear TaperRoller Bearing

0.068 mm (0.00268 in.)

2 REMOVE FRONT TAPER ROLLER BEARING

Using SST, remove the front taper roller bearing

SST 09950- 40011 (09951- 04010, 09952- 04010,

09953- 04030, 09954- 04010, 09955- 04061,09957- 04010, 09958- 04011), 09950- 60010(09951-00330)

NOTICE:

Set the claw of SST to the bearing inner race securely.

3 REMOVE REAR TAPER ROLLER BEARING

Using SST, a press and socket wrench, remove the rear taperroller bearing

SST 09950-00020

NOTICE:

Set the claw of SST to the bearing inner race securely.

4 REMOVE IDLER LOW GEAR AND NEEDLE ROLLER BEARING FROM IDLER GEAR

TR-24

5 REMOVE HIGH AND LOW CLUTCH SLEEVE FROM IDLER GEAR

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.)

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

(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 )

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 ballbearing

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)

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

Mark Thickness mm (in.) Mark Thickness mm (in.)

(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

1 INSPECT SWITCH POSITION

(a) Start the engine, and shift the transfer shift lever to the ”H”position

(b) Check that the center diff indicator light comes on whenthe the switch is in ”ON” position Check that the light goesoff when the switch is in ”OFF” position

2 INSPECT SHIFT LEVER POSITION

(a) Start the engine, and turn the center diff lock switch toOFF

(b) Check that the center diff indicator light comes on whenthe transfer shift lever is shifted to the ”L” position Checkthat the light goes off when the lever is shifted to the ”N”

or ”H” position

3 INSPECT CENTER DIFF LOCK CONTROL RELAY

(a) Check that continuity exists between each terminal, asshown in the chart

Tester connected terminal number Specified condition

*: There is a diode between the terminals 6 and 7

If no continuity exists, check that continuity exists when ing the position of
probe for the position of negative  probe

chang-of tester

(b) Apply battery positive voltage between each terminal andcheck that continuity exists between each terminal, asshown in the chart

Battery voltage applied terminal

Tester connected terminal number Specified condition

1

2 4

3 5

1

4

3 5 2 1

1 2

*

*: Relay housingmetallic parts

D02663

Motor actuator side:

TR-50

4 INSPECT ACTUATOR OPERATION

(a) Raise up the front wheels, place the stopper under therear 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 byhand

neigh-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 Ω

(c) Measure the resistance between the terminals 1 or 5 andbody ground

Standard resistance: More than 0.5 MΩ

If the resistance value is not as specified, replace the motor tuator

123

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 condition

Tester connected terminal number Specified condition

D03520

Center Diff Lock Switch

Center Diff Lock Indicater Light

Transfer Indicator Switch(Center Diff Lock)

MOTOR SHIFT CONTROL SYSTEM

LOCATION

D04346

BallBearing

 Dust Deflector Seal Ring

Rear Output Shaft

Screw PlugBall

Rear Extension HousingDriven Rotor

Speed Sensor Drive Gear

Drive Rotor

Oil Pump Cover

SpringValve Seat

4.9 (50, 43 in.·lbf)

29 (300, 22)

 Oil Seal

 Snap RingSnap Ring

REAR EXTENSION HOUSING

COMPONENTS

1 REMOVE OIL PUMP DRIVE SHAFT

2 REMOVE OIL PUMP COVER

(a) Using a torx socket wrench (T30), remove the 3 screws.(b) Install the 2 suitable bolts to the pump cover

(c) Remove the pump cover from the rear extension housing

3 REMOVE DRIVE ROTOR FROM DRIVEN ROTOR

4 REMOVE DRIVEN ROTOR FROM REAR EXTENSION HOUSING

5 REMOVE SCREW PLUG, SPRING, BALL AND VALVE SEAT

(a) Using a hexagon wrench, remove the screw plug.(b) Using a magnetic finger, remove the spring, ball and valveseat from the rear extension housing

6 REMOVE OIL PUMP PLATE

Remove the 3 bolts and oil pump plate

7 REMOVE SPEED SENSOR DRIVE GEAR

(a) Using a snap ring expander, remove the snap ring.(b) Remove the speed sensor drive gear

8 REMOVE REAR OUTPUT SHAFT

(a) Using a snap ring expander, remove the snap ring.(b) Using SST and a hammer, remove the rear output shaft.SST 09325-12010

(c) Remove the 2 seal rings from the rear output shaft

9 REMOVE DUST DEFLECTOR

(a) Using a screwdriver and hammer, remove the rear sion housing dust deflector

exten-(b) Using a screwdriver and hammer, remove the rear outputshaft dust deflector

10 REMOVE OIL SEAL

Using a screwdriver, pry out the oil seal from the rear extensionhousing

11 REMOVE BALL BEARING

(a) Using a screwdriver, remove the snap ring

(b) Using SST and a press, remove the ball bearing from therear extension housing

SST 09316-6001 1 (09316-00011, 09316-00021)

1 INSPECT DRIVEN ROTOR BODY CLEARANCE

(a) Install the drive rotor and driven rotor to the rear extensionhousing

(b) Using a feeler gauge, measure the body clearance tween the drive rotor and extension housing

be-Standard clearance:

0.08 - 0.17 mm (0.0031 - 0.0067 in.) Maximum clearance:

0.17 mm (0.0067 in.)

If the body clearance exceeds the maximum, replace the driverotor and driven rotor

2 INSPECT DRIVEN ROTOR TIP CLEARANCE

Using a feeler gauge, measure the tip clearance between thedrive rotor and driven rotor

Standard clearance:

0.05 - 0.15 mm (0.0020 - 0.0059 in.) Maximum clearance:

0.15 mm (0.0059 in.)

If the tip clearance exceeds the maximum, replace the drive tor and driven rotor

ro-3 INSPECT OIL PUMP SIDE CLEARANCE

Using a steel straight edge and feeler gauge, measure the sideclearance of oil pump

Standard clearance:

0.03 - 0.10 mm (0.0012 - 0.0039 in.) Maximum clearance:

0.10 mm (0.0039 in.)

If the side clearance exceeds the maximum, replace the driverotor and driven rotor

1 INSTALL BALL BEARING

(a) Using SST and a press, install the ball bearing

SST 09316-6001 1 (09316-00011, 09316-00031)

(b) Select a snap ring that will allow the minimum axial play

(c) Using a screwdriver, install a new snap ring

2 INSTALL DUST DEFLECTOR

(a) Using SST and a hammer, install a new rear extensionhousing dust deflector

SST 09316-6001 1 (09316-00011, 09316-00041)

(b) Using SST and a press, install a new rear output shaftdust deflector

SST 09316-2001 1, 09316-60011 (09316-00011)

3 INSTALL OIL SEAL

(a) Apply MP grease to the lip of a new oil seal

(b) Using SST and a hammer, drive in the oil seal

SST 09316-6001 1 (09316-00011, 09316-00031)

4 INSTALL REAR OUTPUT SHAFT

(a) Using SST and a press, install the rear output shaft.SST 09316- 20011, 09316- 60011 (09316- 00011,

09316-00031)(b) Install the 2 seal rings to the rear output shaft

(c) Select a snap ring that will allow the minimum axial play

(d) Using a snap ring expander, install a new snap ring

5 INSTALL SPEED SENSOR DRIVE GEAR

(a) Install the speed sensor drive gear

(b) Using a snap ring expander, install the snap ring

6 INSTALL OIL PUMP PLATE

(a) Install the oil pump plate

(b) Install and torque the 3 bolts

Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)

7 INSTALL VALVE SEAT, BALL, SPRING AND SCREW PLUG

(a) Apply gear oil to the ball

(b) Install the valve seat, ball and spring

(c) Apply liquid sealer to the screw plug threads

8 INSTALL DRIVEN ROTOR

(a) Apply gear oil to the driven rotor

(b) Install the driven rotor

9 INSTALL DRIVE ROTOR

(a) Apply gear oil to the drive rotor

(b) Install the drive rotor

HINT:

Align the alignment marks

10 INSTALL OIL PUMP COVER

(a) Install the oil pump cover

(b) Using a torx socket wrench (T30), install and torque the

3 screws

Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) NOTICE:

Align the oil hole of the rear extension housing and oil groove end of the oil pump cover.

11 INSTALL OIL PUMP DRIVE SHAFT