Page 1

FOREWORD This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA FJ CRUISER. Applicable models: GSJ 10, 15 series This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fenders of this TOYOTA model are bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collisiondamaged body components of the TOYOTA FJ CRUISER refer to the repair manuals. If you require the above manuals, please contact your TOYOTA dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice.


ABOUT THIS MANUAL Scope of the repair work explanation 

This text explains the welding panel replacement instructions from the vehicle’s white body condition. We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel.

Section categories 

This manual has been divided as shown below. Section Title

Contents

Examples

INTRODUCTION

Explanation of general body repair. Views of weld panel replacement instructions.

Cautionary items. Views of weld panel replacement instructions.

BODY PANEL REPLACEMENT

Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts.

Front side member replacement. Quarter panel replacement.

BODY DIMENSIONS

Body aligning measurements.

Dimension diagrams.

PAINT  COATING

Scope and type of anti-rust treatment, etc. together with weld panel replacement.

Under coating. Body sealer.

Contents omitted in this manual. 

Make sure to perform the following essential procedures, although they are omitted in this manual. (1) Clean and wash removed parts, if necessary. (2) Visual inspection.


INTRODUCTION

IN-1

PRECAUTION GENERAL REPAIR INSTRUCTIONS 1.

WORK PRECAUTIONS

(a) VEHICLE PROTECTION (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers.

Glass Cover

Seat Cover F33000

(b) SAFETY (1) Never stand in a direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable.

WRONG

F33001

(2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening completely. (3) If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line.

WRONG

F33002

(c)

F33003

SAFETY WORK CLOTHES (1) In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands. Code

Name

A

Dust-Prevention Mask

B

Face Protector

C

Eye Protector

D

Safety Shoes

E

Welder’s Glasses

F

Ear Plugs

G

Head Protector

H

Welder’s Gloves


INTRODUCTION

IN-1

PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS

1.

Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are in high demand. At Toyota, in order to fulfill these requirements, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve their strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and their strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized.

F33014

2.

F33015

HEAT REPAIR FOR BODY STRUCTURE PANELS

STRUCTURE PANEL KINKS A sharp deformation angle on a panel that cannot be returned to its original shape by pulling or hammering is called a kink. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended. It is necessary to replace the part where the kink has occurred.


INTRODUCTION

IN-2

3.

F33016

F33017

IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts that help reduce the probability of injury to passengers in side collisions. For impact beams, we use special high tensile strength steel. The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended. If the impact beam or bracket is damaged, replace the door assembly that has the damaged beam. Also, the bumper reinforcement is a necessary and important part that helps reduce the probability of injury to passengers in front collisions, and for the same reasons explained above, should be replaced if damaged.


INTRODUCTION

IN-1

PROPER AND EFFICIENT WORK PROCEDURES

1.

Body Measument Diagrams

REMOVAL

(a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measurements in accordance with the dimensions diagram. Always use a puller to straighten a damaged body or frame.

F33020

(b) CUTTING AREA (1) Always cut in a straight line and avoid cutting reinforced areas.

Cutting Okay

Corners Reinforcement F33021

(c)

WRONG

PRECAUTIONS FOR DRILLING OR CUTTING (1) Check behind any area to be drilled or cut to ensure that there are no hoses, wires, etc., that may be damaged. HINT: See “Handling Precautions on Related Components” on page IN-9.

F33022

(d) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage. HINT: See “Handling Precautions on Related Components” on page IN-9.

F33007


INTRODUCTION

IN-2

2.

PREPARATION FOR INSTALLATION

(a) SPOT WELD POINTS (1) When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding. HINT: Spot welding does not provide sufficient durability for panels with a combined thickness of over 3 mm (0.12 in.)

Less than 3 mm

F10011A

(b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) (1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through primer.

F33008

(c)

MAKING HOLES FOR PLUG WELDING (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding. REFERENCE: mm (in.) Thickness of welded portion

Puncher

Size of plug hole

1.0 (0.04) under

ø 5 (0.20) over

1.0 (0.04) − 1.6 (0.06)

ø 6.5 (0.26) over

1.7 (0.07) − 2.3 (0.09)

ø 8 (0.31) over

2.4 (0.09) over

ø 10 (0.39) over

F33009

(d) SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS (1) When welding, there is a danger that electrical components will be damaged by the electrical current flowing through the body. (2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body. F33023

Air Saw

20 − 30 mm Overlap

F33024

(e) ROUGH CUTTING OF JOINTS (1) For joint areas, rough cut the new parts, leaving 20 − 30 mm (0.79 − 1.18 in.) of overlap.


INTRODUCTION

3.

IN-3

INSTALLATION

(a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing underbody or engine components to ensure correct assembly. After installation, confirm proper fit.

F33025

(b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs. (2) Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than where specified. WRONG

F10017A

(c)

CORRECT

POST-WELDING REFINISHING (1) Always check the welded spots to ensure that they are secure. (2) When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this will weaken the weld.

WRONG F10018A

(d) SPOT WELD LOCATIONS (1) Avoid welding over previously welded areas.

Old Spot Locations

New Spot Locations F33010

Tip Cutter

F10019A

(e) SPOT WELDING PRECAUTIONS (1) The shape of the tip point of the spot welder significantly affects the strength of the weld. Therefore, maintain the tip point in the proper shape, and allow it to cool after every five or six spots. (2) Completely remove the paint from the areas to be spot welded, including the seams and the surfaces that come in contact with the welding tip. (3) Use a sander to remove any burrs that are created during spot welding.


INTRODUCTION

IN-4

4.

Sealer Gun

ANTI-RUST TREATMENT AFTER INSTALLATION (BEFORE PAINTING PROCESS)

(a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc. F33011

(b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from damage by flying stones, always apply sufficient under coating to the bottom surface of the under body and inside of the wheel housings.

F33012

5.

ANTI-RUST TREATMENT AFTER INSTALLATION (AFTER PAINTING PROCESS)

(a) ANTI-RUST AGENT (WAX) APPLICATION (1) To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hood, and around the hinges, or the welded surfaces inside the box-shaped cross sections of the side members, body pillars, etc. F33013


INTRODUCTION

6.

IN-5

ANTI-RUST TREATMENT BY PAINTING REFERENCE:

Painting prevents corrosion and protects the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purposes is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc. HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat.  Apply the anti-chipping paint after the top coat.

 Apply the anti-chipping paint before the second coat. Anti-Chipping Paint

Top Coat Second Coat

Top Coat Second Coat

Anti-Chipping Paint

Under Coat (ED Primer)

Under Coat (ED Primer)

Steel Metal

Steel Metal F10024A


INTRODUCTION

IN-9

HANDLING PRECAUTIONS ON RELATED COMPONENTS 1.

BRAKE SYSTEM The brake system is one of the most important safety components. Always follow the directions and notes given in the brake section of the repair manual for the relevant model year when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system.

2.

DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Body repair must be particularly accurate to ensure correct alignment. HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model year during alignment and in section DI of this section.

3.

Component to be aligned

Section of repair manual for relevant model

Front Wheels

Front Suspension section

Rear Wheels

Rear Suspension section

Propeller Shaft

Propeller Shaft section

COMPONENTS ADJACENT TO THE BODY PANELS Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.  Before repairing the body panels, remove their components or apply protective covers over the components.  Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool tip or blade to prevent damaging the components and the body paint.  Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas. HINT: Apply touch-up paint to any damaged paint surfaces.  Before drilling or cutting sections, make sure that there are no wires, etc., on the reverse side.

4.

ECU (ELECTRONIC CONTROL UNIT) Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs.  Before starting electric welding operations, disconnect the negative (−) terminal cable from the battery. When the negative (−) terminal cable is disconnected from the battery, the memory of the clock and audio systems will be erased. So, before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seats and outside rear view mirrors, which are all equipped with a memory function, it is not possible to make a record of the memory contents. When the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory.  Do not expose the ECUs to ambient temperatures above 80C (176F). NOTICE: Since it is possible that the ambient temperature may reach 80C (176F) or more, remove the ECUs from the vehicle before starting work.  Be careful not to drop the ECUs and not to apply physical shocks to them.


INTRODUCTION

IN-10

DAMAGED VEHICLE DISPOSAL PRECAUTION (SRS AIRBAG SYSTEM) For SRS airbag system adjustment methods, refer to the TOYOTA Repair Manual. (1) When using an electric welder, first remove all airbags and the seat belt pretensioner. (2) If impacts are likely to occur to the front airbag sensor, side airbag sensor, rear airbag sensor or seat position sensor, remove each sensor as necessary beforehand. (3) Do not allow the front airbag sensor, side airbag sensor, rear airbag sensor or seat position sensor to become heated to high temperatures.

COMBINATION METER

SRS WARNING LIGHT FRONT AIRBAG SENSOR RH FRONT PASSENGER AIRBAG ASSEMBLY

FRONT AIRBAG SENSOR LH

SPIRAL CABLE

FRONT PASSENGER SEAT BELT WARNING LIGHT

DLC3 CENTER AIRBAG SENSOR ASSEMBLY

STEERING PAD

PASSENGER AIRBAG ON/OFF INDICATOR

H102141


INTRODUCTION

CURTAIN SHIELD AIRBAG ASSEMBLY (*1)

IN-11

CURTAIN SHIELD AIRBAG ASSEMBLY RH (*1)

REAR AIRBAG SENSOR RH (*1)

SEAT POSITION SENSOR

SIDE AIRBAG SENSOR LH (*1) FRONT SEAT SIDE AIRBAG ASSEMBLY RH (*1) FRONT SEAT OUTER BELT ASSEMBLY LH FRONT SEAT OUTER BELT ASSEMBLY RH

FRONT SEAT SIDE AIRBAG ASSEMBLY LH (*1)

REAR AIRBAG SENSOR LH (*1)

SIDE AIRBAG SENSOR RH (*1)

FRONT SEAT INNER BELT ASSEMBLY LH

OCCUPANT CLASSIFICATION ECU

*1: w/ Side Airbag Assembly and Curtain Shield Airbag Assembly H102142


INTRODUCTION

IN-10

HANDLING PRECAUTIONS OF PLASTIC BODY PARTS 1. 2. 3.

The repair procedure for plastic body parts must conform with the type of plastic material. Plastic body parts are identified by the codes in the following table. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must be given to the properties of the plastic.

Code

Material name

Heat* resistant temperature limit C (F)

ABS

Acrylonitrile Butadiene Styrene

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

ASA

Acrylonitrile Styrene Acrylate

80 (176)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid gasoline and organic or aromatic solvents.

PA

Polyamide (Nylon)

80 (176)

Alcohol and gasoline are harmless.

Avoid battery acid.

PBT

Polybutylene Terephthalate

160 (320)

Alcohol and gasoline are harmless.

Most solvents are harmless.

PC

Polycarbonate

120 (248)

Alcohol is harmless.

Avoid gasoline, brake fluid, wax, wax removers and organic solvents. Avoid alkali.

PP

Polypropylene

80 (176)

Alcohol and gasoline are harmless.

Most solvents are harmless.

Polymethyl Methacrylate

80 (176)

Alcohol is harmless if applied only for short time in small amounts.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

PVC

Polyvinylchloride (Vijnyl)

80 (176)

Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

TSOP

TOYOTA Super Olefine Polymer

80 (176)

Alcohol and gasoline are harmless.

Most solvents are harmless.

PMMA

Resistance to alcohol or gasoline

*Temperatures higher than those listed here may result in material deformation during repair.

Notes


INTRODUCTION

Roof Drip Side Finish Moulding (PVC)

IN-11

Outer Rear View Mirror (ABS/PMMA)

Door Glass Outer Weatherstrip (PP) Cowl Top Ventilator Louver (TSOP)

Radiator Grille (ABS/PP)

Front Valance Panel (TSOP)

Step (TSOP) Front Wheel Opening Extension (TSOP)

Front Bumper Cover (TSOP)

Front Turn Light (PMMA/ASA) Headlight (PC/PP)

Front Bumper Pad (PP)

Rear Combination Light (PMMA/ASA)

Rear Bumper Cover (TSOP) Door Outside Handle (PC/PBT/PA)

Rear Spoiler (ABS) High Mount Stop Light (PMMA) Emblem (ABS)

Front Fender Mudguard (PP) Front Door Outside Moulding (PP) License Plate Light (PC/ASA)

Rocker Panel Moulding (PP) Rear Door Outside Moulding (PP)

Rear Bumper Lower Cover (TSOP) Back Door Outside Moulding (PP)

Quarter Outside Moulding (PP) Rear Reflex Reflector (PMMA/ASA)

Quarter Panel Mudguard (PP)

Rear Bumper Pad (TSOP)

F30209


INTRODUCTION

IN-14

ABOUT THIS VEHICLE 1. STRUCTUAL OUTLINE . . . 590Mpa High strength steel . . . 440Mpa High strength steel

. . . Formed material application areas (refer to PC-8, 9)

F30207


INTRODUCTION

IN-15

NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE 1.

NOTICE FOR USING JACK AND SAFETY STAND

Front

JACK POSITION SUPPORT POSITION CENTER OF VEHICLE GRAVITY

B144209


IN-16

2.

INTRODUCTION

NOTICE FOR USING SWING ARM TYPE LIFT

Center of Lift

CENTER OF VEHICLE GRAVITY (Unloaded condition)

B144198


INTRODUCTION

IN-17

DAMAGE DIAGNOSIS

Confirmation Point

Collision Direction

Collision Force Absorption Direction

0240B018C


INTRODUCTION

IN-18

COMPORNENTS 1.

Front bumper

3.0 (30, 27 in..lbf)

RADIATOR GRILLE

3.0 (30, 27 in..lbf) FRONT BUMPER COVER

8.0 (80, 71 in..lbf)

3.0 (30, 27 in..lbf)

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft.lbf) : Specified torque

B134727


INTRODUCTION

IN-19

FRONT BUMPER SIDE RETAINER RH

3.0 (30, 27 in..lbf)

FRONT BUMPER FILLER RH

FRONT BUMPER FILLER LH

3.0 (30, 27 in..lbf) FRONT BUMPER UPPER RETAINER

FRONT BUMPER SIDE SUPPORT LH

8.0 (80, 71 in..lbf)

65 (665, 48)

FRONT BUMPER EXTENSION RH FRONT BUMPER EXTENSION LH 65 (665, 48) 65 (665, 48)

65 (665, 48)

FRONT BUMPER REINFORCEMENT

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft.lbf) : Specified torque B134728


INTRODUCTION

IN-20

2.

Rear bumper

8.0 (80, 71 in..lbf)

WIRE to WIRE CONNERCTOR

REAR BUMPER COVER

WIRE to WIRE CONNERCTOR

3.0 (30, 27 in..lbf)

8.0 (80, 71 in..lbf)

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft.lbf) : Specified torque B135139


INTRODUCTION

IN-21

REAR BUMPER ENERGY ABSORBER

REAR BUMPER UPPER RETAINER RH

3.0 (30, 27 in..lbf)

REAR BUMPER END RETAINER RH 3.0 (30, 27 in..lbf)

REAR BUMPER SIDE STAY RH

8.0 (80, 71 in..lbf) REAR BUMPER SIDE SUPPORT SUB-ASSEMBLY RH 8.0 (80, 71 in..lbf) 8.0 (80, 71 in..lbf) 3.0 (30, 27 in..lbf) REAR BUMPER BAR BRACKET RH

REAR BUMPER UPPER RETAINER LH 8.0 (80, 71 in..lbf) REAR BUMPER BAR BRACKET LH

REAR BUMPER SIDE SUPPORT SUB-ASSEMBLY LH

REAR BUMPER SIDE STAY LH REAR BUMPER END RETAINER LH

8.0 (80, 71 in..lbf) 3.0 (30, 27 in..lbf)

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft.lbf) : Specified torque B138425


INTRODUCTION

IN-22

3.

Instrument panel INSTRUMENT PANEL FINISH PANEL END LH NO.2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY

2.5 (25, 22 in..lbf)

NO.1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY 2.5 (25, 22 in..lbf) FRONT NO.2 SPEAKER ASSEMBLY

FRONT NO.2 SPEAKER ASSEMBLY

20 (204, 15)

INSTRUMENT PANEL SUB-ASSEMBLY INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY RH COMBINATION METER ASSEMBLY

NO.2 INSTRUMENT PANEL REGISTER ASSEMBLY

7.0 (71, 62 in..lbf) CLIP NO.1 INSTRUMENT PANEL REGISTER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL

GLOVE COMPARTMENT DOOR ASSEMBLY

LOWER INSTRUMENT PANEL LH INSTRUMENT PANEL GARNISH LH

INTEGRATION CONTROL AND PANEL ASSEMBLY CONSOLE UPPER PANEL NO.1 GARNISH LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH

INSTRUMENT PANEL GARNISH RH

2.5 (25, 22 in..lbf)

RADIO RECEIVER ASSEMBLY INSTRUMENT LOWER COVER SUB-ASSEMBLY

HOOD LOCK CONTROL LEVER SUB-ASSEMBLY

CLIP

CLIP CAUTION: The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft.lbf)

: Specified torque B133847


INTRODUCTION

IN-23

w/ Accessory Meter: NO.2 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY

METER COVER

ACCESSORY METER ASSEMBLY

ACCESSORY METER BRACKET CLIP INSTRUMENT PANEL LOWER INSTRUMENT PANEL SUB-ASSEMBLY RH INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY

LOWER INSTRUMENT PANEL SUB-ASSEMBLY LH

INSTRUMENT CLUSTER LOWER CENTER FINISH PANEL SUB-ASSEMBLY INSTRUMENT PANEL CENTER BRACKET SUB-ASSEMBLY

for Automatic Transmission 2WD: CONSOLE UPPER REAR PANEL SUB-ASSEMBLY

GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY for Manual Transmission 4WD: SHIFT LEER KNOB SUB-ASSEMBLY SHIFT LEVER KNOB SUB-ASSEMBLY CONSOLE UPPER REAR PANEL SUB-ASSEMBLY

PARKING BRAKE HOLE COVER SUB-ASSEMBLY for Automatic Transmission 4WD: SHIFT LEVER KNOB SUB-ASSEMBLY CONSOLE UPPER REAR PANEL SUB-ASSEMBLY

PARKING BRAKE HOLE COVER SUB-ASSEMBLY

BOX BOTTOM MAT

PARKING BRAKE HOLE COVER SUB-ASSEMBLY FRONT CONSOLE BOX B133848


INTRODUCTION

IN-24

4.

Interior trim

ASSIST GRIP ASSEMBLY

COAT HOOK COAT HOOK

ASSIST GRIP PLUG

ASSIST GRIP ASSEMBLY

ASSIST GRIP PLUG w/ Curtain Shield Airbag:

ROOF HEADLINING HOLE PLUG

ROOF SIDE RAIL GARNISH RH FRONT PILLAR GARNISH RH

ROOF SIDE INNER GARNISH COVER RH ASSIST GRIP PLUG

FRONT DOOR OPENING TRIM WEATHERSTRIP RH ASSIST GRIP ASSEMBLY

ACCESS DOOR SCUFF PLATE RH COWL SIDE TRIM BOARD RH

FRONT DOOR SCUFF PLATE RH

B130660


INTRODUCTION

IN-25

FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY

42 (430, 31)

42 (430, 31)

CENTER PILLAR UPPER GARNISH

PRETENSIONER CONNECTOR ACCESS PANEL REAR WEATHERSTRIP FRONT SEAT OUTER BELT ASSEMBLY 42 (430, 31) 8.5 (85, 75 in..lbf) for LH Side: TENSION REDUCER CONNECTOR

ACCESS DOOR TRIM BOARD SUB-ASSEMBLY 42 (430, 31) 8.5 (85, 75 in..lbf)

42 (430, 31) FRONT SEAT OUTER BELT ASSEMBLY

PRETENSIONER CONNECTOR

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft.lbf)

: Specified torque B135086


INTRODUCTION

IN-26

42 (430, 31)

REAR SEAT OUTER BELT ASSEMBLY

ROOF SIDE INNER GARNISH DECK TRIM SIDE PANEL ASSEMBLY

PACKAGE HOLDER NET HOOK

8.5 (85, 75 in..lbf) 42 (430, 31)

42 (430, 31)

for RH Side: LAP BELT OUTER ANCHOR COVER

w/ Power Outlet Socket:

SIDE TRIM COVER QUARTER TRIM POCKET

REAR DECK TRIM COVER QUARTER TRIM POCKET TRAY

POWER OUTLET CONNECTOR

w/ Woofer:

8.1 (85, 72 in..lbf)

AMPLIFIER BOX SPEAKER ASSEMBLY

SPEAKER CONNECTOR SPEAKER MOUNTING COVER DECK SIDE GARNISH CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft.lbf)

: Specified torque

B134993


INTRODUCTION

5.

IN-27

Front seat

for Front Passenger Side:

FRONT SEAT INNER BELT ASSEMBLY

FRONT SEAT ASSEMBLY

42 (430, 31) FRONT SEAT INNER BELT ASSEMBLY

37 (375, 27)

FRONT SEAT TRACK COVER

FLOOR WIRE

w/ Front Seat Side Airbag:

FLOOR WIRE

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft.lbf)

: Specified torque

B130663


INTRODUCTION

IN-28

6.

Rear seat

for RH Side:

REAR SEATBACK ASSEMBLY

37 (375, 27)

42 (430, 31) 37 (375, 27)

REAR SEATBACK BOARD CARPET ASSEMBLY

REAR SEAT INNER BELT ASSEMBLY REAR CENTER SEAT INNER BELT ASSEMBLY

for LH Side: 42 (430, 31)

37 (375, 27)

REAR SEATBACK ASSEMBLY

REAR SEAT INNER BELT ASSEMBLY

REAR SEATBACK BOARD CARPET ASSEMBLY 37 (375, 27)

CAUTION: The bolts must be tightened to the torque specification, as they are related to vehicle safety during a collision. N.m (kgf.cm, ft.lbf)

: Specified torque B130654


DIFFERENTIAL – DIFFERENTIAL SYSTEM

DF–1

DIFFERENTIAL SYSTEM PRECAUTION 1.

Before disassembling the differential assembly, thoroughly clean it to remove any sand, mud or foreign matter. This will help prevent contamination during disassembly and reassembly. 2. When removing the rear differential carrier cover or any other light alloy part, do not pry it off with a screwdriver or other tool that may cause damage. Instead, tap the part with a plastic-faced hammer. 3. Always arrange disassembled parts in the order they were removed and protect them from foreign matter. 4. Before installation of each part, thoroughly clean and dry it. Then apply hypoid gear oil LSD to it. Do not use alkaline chemicals to clean aluminum parts, rubber parts or ring gear set bolts. Also, do not use white gasoline or other cleaning oils to clean Orings, oil seals or rubber parts. 5. Coat sliding surfaces or rotating parts with hypoid gear oil LSD. 6. Do not fix a part directly in a vise. Place aluminum plates between the part and vise. 7. Be careful not to damage the contact surfaces of the case. Such damage may cause oil leakage. 8. Before applying sealant, remove deposited oil sealant and clean the part to be sealed using white gasoline. 9. After sealing parts, do not allow oil to come into contact with the seal for at least an hour. 10. Do not allow scratches on surfaces which contact an oil seal, O-ring or gasket. Scratches may lead to oil leakage. 11. When press-fitting an oil seal, be careful not to damage the lip of the oil seal or its outside periphery. 12. When replacing a bearing, replace the inner and outer races as a set.

DF


DF–2

DIFFERENTIAL – DIFFERENTIAL SYSTEM

PROBLEM SYMPTOMS TABLE Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Differential system Symptom

Oil leak from front differential

Oil leak from rear differential

Oil leak from front drive pinion shaft

Oil leak from rear drive pinion shaft

Differential lock does not operate

DF

Suspected area

See page

1. Oil (level too high or wrong grade)

DF-3

2. Front differential side oil seal (worn or damaged)

DF-23

3. Front differential rear oil seal (worn or damaged)

DF-24

4. Companion flange (loose or damaged)

DF-22

1. Oil (level too high or wrong grade)

DF-3

2. Rear differential front oil seal (worn or damaged)

DF-9

3. Companion flange (loose or damaged)

DF-48

1. Oil (level too high or wrong grade)

DF-3

2. Front differential side oil seal (worn or damaged)

DF-13

3. Front differential rear oil seal (worn or damaged)

DF-5

4. Companion flange (loose or damaged)

DF-22

1. Oil (level too high or wrong grade)

DF-3

2. Rear differential front oil seal (worn or damaged)

DF-9

3. Companion flange (loose or damaged)

DF-48

1. Differential lock switch

DF-102

2. Rear differential lock actuator

DF-102

3. Four wheel drive control ECU

DF-101

4. Differential carrier (Faulty)

-

5. Wiring or ground (Faulty)

-


DF–3

DIFFERENTIAL – DIFFERENTIAL OIL

DIFFERENTIAL OIL ON-VEHICLE INSPECTION 1.

0 to 5 mm D025304E05

CHECK DIFFERENTIAL OIL (a) Stop the vehicle on a level surface. (b) Remove the differential filler plug and gasket. (c) Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the differential filler plug hole. NOTICE: • After changing the oil seal, drive the vehicle and then check the oil level again. • Too much or too little oil will lead to differential problems. HINT: If necessary, fill the differential carrier assembly with hypoid gear oil. Recommended viscosity Item

Temperature

Viscosity

Front w/ A.D.D. Front differential for w/o A.D.D. Rear differential

SAE 75W-90

Above -18°C (-0.4°F)

SAE 90

Below -18°C (-0.4°F)

SAE 85W-90

Oil grade Item

Grade

Front differential (4WD)

Hypoid gear oil API GL-4 or GL-5

Front differential (2WD) Rear differential (all type)

Hypoid gear oil API GL-5

Front differential oil capacity Item

Capacity

w/o A.D.D.

1.35 to 1.45 liters (1.42 to 1.53 US qts., 1.18 to 1.27 Imp. qts.)

w/ A.D.D.

1.45 to 1.55 liters (1.53 to 1.63 US qts., 1.27 to 1.36 Imp. qts.)

Rear differential oil capacity Item

Capacity

w/ Differential lock

2.85 to 2.95 liters (3.01 to 3.12 US qts, 2.51 to 2.60 Imp. qts.)

w/o Differential lock.

2.95 to 3.05 liters (3.12 to 3.22 US qts, 2.60 to 2.68 Imp. qts.)

(d) Check for oil leakage when the oil level is low. (e) Install the differential filler plug with a new gasket. Torque: Front differential 39 N*m (400 kgf*cm, 29 ft.*lbf) Rear differential 49 N*m (500 kgf*cm, 36 ft.*lbf)

DF


DF–4

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER OIL SEAL

FRONT DIFFERENTIAL CARRIER OIL SEAL DRIVE LINE DIFFERENTIAL

COMPONENTS FRONT DRIVE PINION COMPANION FLANGE NUT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT DIFFERENTIAL DUST DEFLECTOR FRONT DIFFERENTIAL CARRIER OIL SEAL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)

FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER) 370 (3,770, 273) or less

FRONT DIFFERENTIAL OIL STORAGE RING FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

FRONT DIFFERENTIAL CARRIER SUB-ASSEMBLY

DF N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

MP grease C113270E02


DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER OIL SEAL

DF–5

REMOVAL

SST

1.

REMOVE NO. 1 ENGINE UNDER COVER (See page EM-6)

2.

REMOVE REAR ENGINE UNDER COVER ASSEMBLY (a) Remove the 4 bolts, then remove the rear engine under cover.

3.

REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR-2)

4.

REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT (a) Using SST and a hammer, loosen the staked part of the nut. SST 09930-00010

C089309E01

(b) Using SST to hold the companion flange, remove the nut. SST 09330-00021 (09330-00030) SST

B087842E02

5.

REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) NOTICE: Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

6.

REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal. SST 09308-10010

7.

REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

SST F040720E01

Oil Seal

Oil Slinger

SST F040717E01

DF


DF–6

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER OIL SEAL

8.

SST

REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST, remove the roller bearing (inner). SST 09556-22010

F044343E01

(b) Using SST, tap out the roller bearing (outer). SST 09308-00010

SST

9.

REMOVE FRONT DIFFERENTIAL OIL STORAGE RING (a) Using a screwdriver and hammer, tap out the oil storage ring.

10. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER W001770E01

INSTALLATION 1.

INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new bearing spacer. HINT: Install the spacer in the correct direction.

2.

INSTALL FRONT DIFFERENTIAL OIL STORAGE RING (a) Using a brass bar and hammer, tap in a new oil storage ring. NOTICE: Be careful not to damage the oil storage ring.

3.

INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST and a hammer, install the roller bearing (outer). SST 09316-60011 (09316-00011, 09316-00021) (b) Install the roller bearing (inner).

4.

INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

C093595E01

SST

DF

G021735E01


DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER OIL SEAL Oil Seal Depth

DF–7

5.

INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Apply MP grease to the lip of a new oil seal. (b) Using SST and a hammer, tap in the oil seal. SST 09554-22010 Oil seal depth: 3.9 to 4.8 mm (0.152 to 0.188in.)

6.

INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, instal the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) NOTICE: Before using SST (center bolt), apply hypoid gear oil to its threads and tip. (b) Using SST to hold the companion flange, install the nut. SST 09330-00021 (09330-00030) Torque: 370 N*m (3,770 kgf*cm, 273 ft.*lbf) or less

7.

INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wench, measure the preload. Preload (at starting)

SST F040719E03

SST F040716E01

Item

Specified Condition

New bearing

0.98 to 1.57 N*m (10 to 16 kgf*cm, 8.7 to 13.9 in.*lbf)

Used bearing

0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf)

If the result is not as specified, adjust the preload.

C089308E01

8.

STAKE FRONT DRIVE PINION COMPANION FLANGE NUT (a) Using a chisel and hammer, stake the nut.

9.

INSTALL FRONT PROPELLER SHAFT ASSEMBLY (See page PR-6)

10. ADD DIFFERENTIAL OIL (See page DF-3) 11. CHECK FOR DIFFERENTIAL OIL LEAKAGE C089310E01

12. INSTALL REAR ENGINE UNDER COVER ASSEMBLY (a) Install the rear engine under cover with the 4 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 13. INSTALL NO. 1 ENGINE UNDER COVER (See page EM-7)

DF


DF–8

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL

REAR DIFFERENTIAL CARRIER OIL SEAL DRIVE LINE DIFFERENTIAL

COMPONENTS

REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (OUTER) REAR DIFFERENTIAL DRIVE PINION OIL SLINGER REAR DIFFERENTIAL CARRIER OIL SEAL

DIFFERENTIAL OIL STORAGE RING REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (INNER)

REAR DIFFERENTIAL DUST DEFLECTOR REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

DF

REAR DRIVE PINION NUT 370 (3,770, 273) or less

N*m (kgf*cm, ft*lbf) : Specified torque

Non-reusable part

MP grease C135464E01


DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL

DF–9

REMOVAL

SST

1.

REMOVE REAR PROPELLER SHAFT ASSEMBLY (for 2WD) (See page PR-9)

2.

REMOVE PROPELLER SHAFT ASSEMBLY (for 4WD) (See page PR-9)

3.

REMOVE REAR DRIVE PINION NUT (a) Using SST and a hammer, loosen the staked part of the nut. SST 09930-00010

C089309E01

(b) Using SST to hold the companion flange in place, remove the nut. SST 09330-00021 (09330-00030) SST

B087842E02

4.

REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) NOTICE: Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

5.

REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal. SST 09308-10010

6.

REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

SST F040720E01

Oil Seal

Oil Slinger

DF SST F040717E01


DF–10

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL

7.

SST

REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST, remove the roller bearing (inner). SST 09556-22010

F044343E01

(b) Using SST, tap out the roller bearing (outer). SST 09308-00010

SST

8.

REMOVE DIFFERENTIAL OIL STORAGE RING (a) Using a screwdriver and hammer, tap out the oil storage ring.

9.

REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

W001770E02

INSTALLATION 1.

INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new bearing spacer. HINT: Install the spacer in the correct direction.

2.

INSTALL DIFFERENTIAL OIL STORAGE RING (a) Using a brass bar and hammer, tap in a new oil storage ring. NOTICE: Be careful not to damage the oil storage ring.

3.

INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST and hammer, tap in the roller bearing (outer). SST 09316-60011 (09316-00011, 09316-00021) (b) Install the roller bearing (inner).

4.

INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

C093595E01

SST

DF

G021735E01


DF–11

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL Oil Seal Depth

5.

INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL (a) Apply MP grease to the lip of a new oil seal. (b) Using SST and hammer, tap in the oil seal. SST 09554-30011 Oil seal depth: 0.55 to 1.45 mm (0.021 to 0.057 in.)

6.

INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, install the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) NOTICE: Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

SST F040719E03

SST F040716E01

(b) Using SST to hold the companion flange in place, install the nut. SST 09330-00021 (09330-00030) Torque: 370 N*m (3,770 kgf*cm, 273 ft.*lbf) or less

SST

B087843E01

7.

INSTALL DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload. Preload (at starting) Item

Specified Condition

New bearing

1.05 to 1.64 N*m (11 to 17 kgf*cm, 9.3 to 15 in.*lbf)

Reused bearing

0.56 to 0.85 N*m (6 to 9 kgf*cm, 4.9 to 7.5 in.*lbf)

If the result is not as specified, adjust the preload.

C089308E01

8.

STAKE DRIVE PINION NUT (a) Using a chisel and hammer, stake the nut.

9.

INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 2WD) (See page PR-14)

10. INSTALL PROPELLER SHAFT ASSEMBLY (for 4WD) (See page PR-14) 11. ADD DIFFERENTIAL OIL (See page DF-3) C089310E01

12. CHECK FOR DIFFERENTIAL OIL LEAKAGE

DF


DF–12

DIFFERENTIAL – FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL DRIVE LINE DIFFERENTIAL

COMPONENTS

FRONT DRIVE SHAFT ASSEMBLY RH

FRONT DIFFERENTIAL CARRIER ASSEMBLY

SNAP RING

DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL RH

DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL LH

SNAP RING

FRONT DRIVE SHAFT ASSEMBLY LH

DF Non-reusable part

MP grease C113271E02


DIFFERENTIAL – FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

DF–13

REMOVAL HINT: The procedure described below is for the LH side. Use the same procedure for both the RH and LH sides, unless otherwise specified. 1.

REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-3)

2.

REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, tap out the oil seal. SST 09308-10010

SST C097017E01

DF


DF–14

DIFFERENTIAL – FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

INSTALLATION HINT: The procedure described below is for the RH side. Use the same procedure for both the LH and RH sides, unless otherwise specified. 1. RH Side

LH Side Differential Seal

2. B084278E01

DF

INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Apply MP grease to 2 new oil seals. (b) Using SST and a hammer, tap in the 2 oil seals. NOTICE: Make sure the LH and RH oil seals are installed in the proper locations. SST 09550-00032, 09950-70010 (09951-07100) Oil seal depth Side

Oil Seal Depth

LH side

-0.45 to 0.45 mm (-0.118 to 0.118 in.)

RH side

4.8 to 5.8 mm (0.189 to 0.229 in.)

INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9)


DF–14

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

FRONT DIFFERENTIAL CARRIER ASSEMBLY DRIVE LINE DIFFERENTIAL

COMPONENTS w/ A.D.D.

FRONT DIFFERENTIAL BREATHER HOSE

FRONT DIFFERENTIAL TUBE ASSEMBLY

13 (133, 10)

SNAP RING

FRONT PROPELLER SHAFT ASSEMBLY

FRONT DRIVE SHAFT ASSEMBLY RH 88 (899, 65)

FRONT DIFFERENTIAL CARRIER ASSEMBLY

FRONT DIFFERENTIAL MOUNT STOPPER UPPER FRONT NO. 2 DIFFERENTIAL SUPPORT

FRONT NO. 3 DIFFERENTIAL SUPPORT

108 (1,100, 80)

x2 87 (887, 64)

FRONT NO. 1 DIFFERENTIAL MOUNT NUT

160 (1,630, 118)

SNAP RING

FRONT DIFFERENTIAL MOUNT STOPPER LOWER 186 (1,900, 137)

DF

137 (1,400, 101)

N*m (kgf*cm, ft.*lbf) : Specified torque

FRONT NO. 1 DIFFERENTIAL SUPPORT

FRONT DRIVE SHAFT ASSEMBLY LH

Non-reusable part C113173E02


DF–15

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY 13 (133, 10)

w/o A.D.D.

FRONT DIFFERENTIAL BREATHER TUBE

FRONT DIFFERENTIAL BREATHER HOSE SNAP RING

FRONT PROPELLER SHAFT ASSEMBLY FRONT DRIVE SHAFT ASSEMBLY RH 88 (899, 65)

FRONT DIFFERENTIAL CARRIER ASSEMBLY FRONT NO. 3 DIFFERENTIAL SUPPORT

x2

108 (1,100, 80)

FRONT DIFFERENTIAL MOUNT STOPPER UPPER 87 (887, 64)

FRONT NO. 1 DIFFERENTIAL MOUNT NUT

SNAP RING FRONT NO. 2 DIFFERENTIAL SUPPORT

160 (1,630, 118)

FRONT NO. 1 DIFFERENTIAL SUPPORT FRONT DIFFERENTIAL MOUNT STOPPER LOWER

186 (1,900, 137)

FRONT DRIVE SHAFT ASSEMBLY LH

137 (1,400, 101)

N*m (kgf*cm, ft.*lbf) : Specified torque

DF

Non-reusable part C116214E03


DF–16

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

w/ A.D.D. DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL RH FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH

DIFFERENTIAL CLUTCH SLEEVE SIDE GEAR SHAFT HOLE SNAP RING DIFFERENTIAL CLUTCH HUB SNAP RING

110 (1,120, 81)

NEEDLE BEARING

FRONT DIFFERENTIAL TUBE ASSEMBLY

FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR

DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY SIDE GEAR INTERMEDIATE SHAFT HOLE SNAP RING 21 (210, 15)

DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY

DF N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

MP grease C113174E02


DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

DF–17

w/o A.D.D.

DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL RH

FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING

DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH SNAP RING SNAP RING

FRONT DIFFERENTIAL TUBE ASSEMBLY

110 (1,120, 81)

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

MP grease C116213E03

DF


DF–18

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

FRONT DRIVE PINION COMPANION FLANGE NUT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT DIFFERENTIAL DUST DEFLECTOR FRONT DIFFERENTIAL CARRIER OIL SEAL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (INNER)

FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (OUTER)

FRONT DIFFERENTIAL OIL STORAGE RING

370 (3,770, 273) or less

FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (OUTER)

FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (INNER)

DRIVE PINION WASHER DIFFERENTIAL DRIVE PINION

DF N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

MP grease C113175E02


DF–19

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

50 (510, 37)

DIFFERENTIAL SIDE BEARING RETAINER CASE WASHER

x10

FRONT DIFFERENTIAL CASE BEARING (OUTER) FRONT DIFFERENTIAL CASE BEARING (INNER) 97 (985, 71)

DIFFERENTIAL CASE ASSEMBLY x10

DIFFERENTIAL RING GEAR FRONT DIFFERENTIAL CARRIER ASSEMBLY

w/ A.D.D. : FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING

GASKET

DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL LH

FILLER PLUG 39 (400, 29)

GASKET DRAIN PLUG STRAIGHT PIN

65 (660, 48)

PINION GEAR SIDE GEAR

PINION SHAFT

SIDE GEAR THRUST WASHER PINION GEAR THRUST WASHER

DF

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part

MP grease C113870E03


DF–20

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL 1.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2.

REMOVE FRONT WHEEL

3.

REMOVE NO.1 ENGINE UNDER COVER SUBASSEMBLY

4.

REMOVE REAR ENGINE UNDER COVER ASSEMBLY

5.

DRAIN DIFFERENTIAL OIL

6.

REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR-2)

7.

SEPARATE SPEED SENSOR FRONT LH (See page DS-3)

8.

SEPARATE FRONT SPEED SENSOR RH HINT: Use the same procedure as for the RH side.

9.

REMOVE FRONT AXLE HUB GREASE CAP LH (See page DS-3)

10. REMOVE FRONT AXLE HUB GREASE CAP RH HINT: Use the same procedure as for the RH side. 11. SEPARATE TIE ROD END SUB-ASSEMBLY LH (See page DS-3) 12. SEPARATE TIE ROD END SUB-ASSEMBLY RH 13. SEPARATE FRONT LOWER BALL JOINT ATTACHMENT (See page DS-4) 14. REMOVE FRONT AXLE HUB NUT LH (See page DS3) 15. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedure as for the RH side. 16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-4) 17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH HINT: Use the same procedure as for the RH side.

DF

Mounting Bolt

Mounting Bolt

Mounting Nut C097020E01

18. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (a) Remove the bolt and disconnect the differential breather tube bracket. (b) Support the differential with a jack. (c) Remove the No. 1 differential mounting nut. (d) Remove the 2 mounting bolts and 2 nuts. (e) Lower the jack and remove the front differential.


DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

(f)

DF–21

Remove the 3 bolts and front No. 1 differential support.

B084273E02

(g) Remove the 2 bolts and front No. 2 differential support.

B084274E01

(h) Remove the 2 bolts and front No. 3 differential support.

B084275E01

DISASSEMBLY 1. SST

R012683E01

INSPECT DIFFERENTIAL RING GEAR BACKLASH (a) Using SST and a dial indicator, measure the ring gear backlash. SST 09564-32011 Standard: 0.11 to 0.21 mm (0.0043 to 0.0083 in.) If the backlash is not as specified, adjust the side bearing preload or repair as necessary. HINT: Perform the measurements at 3 or more positions around the side bearing preload.

DF


DF–22 Vertical Runout

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY Lateral Runout

2.

INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using a dial indicator, measure the runout of the companion flange vertically and laterally. Maximum runout Runout

30 mm (1.18 in.)

Maximum

Vertical runout

0.10 mm (0.0039 in.)

Lateral runout

0.10 mm (0.0039 in.)

If the runout is greater than the maximum, replace the companion flange.

F001237E05

3.

INSPECT DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. HINT: Bolts without torque specifications are shown in the service data (see page SS-43).

4.

INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. HINT: Bolts without torque specifications are shown in the service data (see page SS-43). If necessary, disassemble and inspect the differential.

5.

REMOVE DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY (a) Remove the 4 bolts. (b) Using a hammer, pry out the actuator from the differential tube.

6.

REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY (a) Remove the 4 bolts. (b) Using a plastic-faced hammer, tap out the differential tube.

FA01158E01

FA01158E01

G023135E01

DF

C097021E01


DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

DF–23

7.

REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, tap out the oil seal. SST 09308-00010

8.

REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY (a) Using SST, remove the inter shaft. SST 09350-20015 (09369-20040), 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011) (b) Remove the snap ring from the inter shaft.

9.

REMOVE FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR (a) Using a screwdriver with its tip wrapped in protective tape, pry out the bearing retainer deflector.

SST

F044345E01

G023136E01

G023164E01

10. REMOVE FRONT DRIVE PINION COMPANION FLANGE NUT (a) Using SST and a hammer, loosen the staked part of the nut. SST 09930-00010

SST

F044346E01

SST

SA02349E03

(b) Using SST to hold the companion flange in place, remove the nut. SST 09330-00021

DF


DF–24

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

11. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) NOTICE: Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

SST

B087869E01

12. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR (a) Using SST and a press, press out the dust deflector. SST 09950-00020, 09950-60010 (09951-00510), 09950-70010 (09951-07150) NOTICE: Do not drop the companion flange.

SST

F040564E02

13. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal from the differential carrier. SST 09308-10010

SST

14. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER (a) Remove the oil slinger from the drive pinion. SA02348E02

15. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST, remove the roller bearing (inner) from the drive pinion. SST 09556-22010 (b) Remove the bearing spacer.

SST

16. REMOVE DIFFERENTIAL SIDE BEARING RETAINER (a) Remove the 10 bolts and tap out the retainer with a plastic-faced hammer. Z000641E01

17. REMOVE DIFFERENTIAL CASE ASSEMBLY 18. REMOVE DIFFERENTIAL DRIVE PINION

DF


DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

SST

R002482E01

DF–25

19. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST and a press, press out the roller bearing (inner) from the drive pinion. SST 09950-00020 NOTICE: Do not drop the drive pinion. HINT: If the drive pinion or ring gear is damaged, replace them as a set. 20. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using a brass bar and hammer, tap out the roller bearing (outer).

R013226E01

21. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST, remove the roller bearing (outer). SST 09502-12010, 09612-65014 (09612-01020, 09612-01050) SST

22. REMOVE FRONT DIFFERENTIAL OIL STORAGE RING (a) Using a brass bar and hammer, tap out the oil storage ring.

R013210E01

SST

F044347E01

23. REMOVE FRONT DIFFERENTIAL CASE BEARING HINT: • Measure the thickness of the case washer. • Tag the bearing outer races to show the location for reassembly. (a) Using SST and a press, press out the case bearing (outer race) and plate washer from the bearing retainer. SST 09950-60020 (09951-00680), 09950-70010 (09951-07150) If the bearing is damaged during removal, replace it. (b) Using SST and a press, press out the case bearing (outer race) and plate washer from the differential carrier. SST 09950-60020 (09951-00680), 09950-70010 (09951-07150) If the bearing is damaged during removal, replace it.

SST

F044348E01

DF


DF–26

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY Matchmark

24. REMOVE DIFFERENTIAL RING GEAR (a) Place matchmarks on the ring gear and differential case. (b) Remove the 10 ring gear set bolts.

C113176E01

(c) Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.

C014054E01

SST

Notch

R011392E01

25. REMOVE FRONT DIFFERENTIAL CASE BEARING HINT: The differential case and case bearings should only be removed when replacement is necessary. (a) Using SST, remove the 2 case bearings (inner) from the differential case. SST 09950-60010 (09951-00480), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09953-04020, 09958-04011) HINT: Fix the claws of SST to the notch in the differential case assembly. 26. DISASSEMBLE DIFFERENTIAL CASE (a) Using a chisel and hammer, unstake the differential case.

C080046E01

DF


DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

DF–27

(b) Using a pin punch and hammer, tap out the straight pin.

G020264E01

(c) Remove the following parts from the differential case.

B084283E01

(2)

(4)

(1)

(5)

(3) (5)

(4)

(1)

(2)

F044349E01

(1) Differential pinion gear (2 pieces) (2) Differential pinion gear thrust washer (2 pieces) (3) Differential pinion shaft (4) Differential side gear (2 pieces) (5) Differential side gear thrust washer (2 pieces) 27. INSPECT DIFFERENTIAL GEAR KIT (a) Check that the differential pinion and differential side gear are not damaged. If the differential pinion or differential side gear is damaged, replace the differential gear kit. 28. INSPECT FRONT DIFFERENTIAL CASE (a) Check that the differential case is not damaged. If the differential case is damaged, replace it. 29. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING (a) Using a brass bar and hammer, tap out the 2 bearings.

SA00353E01

DF


DF–28

DIFFERENTIAL – FRONT DIFFERENTIAL CARRIER ASSEMBLY

30. REMOVE DIFFERENTIAL CLUTCH HUB (a) Using a snap ring expander, remove the snap ring. (b) Remove the differential clutch hub.

G023137E01

31. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, tap out the oil seal from the differential tube. SST 09308-00010

SST F044350E01

32. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUBASSEMBLY RH (a) Using a snap ring expander, remove the snap ring. (b) Remove the shaft from the differential tube.

C097022E01

33. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING (a) Using a snap ring expander, remove the snap ring. (b) Using SST, a brass bar and a press, press out the shaft RH bearing. SST 09950-00020 NOTICE: • Do not damage the bearing. • Do not drop the shaft.

SST

R013420E01

34. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB (a) Check that there is no wear or damage on the clutch hub and clutch sleeve. Replace parts as necessary. (b) Check that the clutch sleeve slides smoothly on the clutch hub. Replace parts as necessary.

DF

G023141E01


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2010 TOYOTA FJ CRUISER Service Repair Manual  
2010 TOYOTA FJ CRUISER Service Repair Manual  
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