Toyota LAND CRUISER Service Manual Supplement
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Toyota LAND CRUISER Service Manual Supplement

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Table of Contents

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  • Page 2 CAUTION This manual does not include all the necessary items about repair and service, this manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non-specialized or uncertified technicians perform repair or service only using this manu- al or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer's vehicle.
  • Page 3 FOREWORD This supplement has been prepared to provide information covering general service repairs for the chassis and body of the TOYOTA LAND CRUISER (Hardtop, Canvas Top and Sta- tion Wagon) which underwent changes in August, 1992. Applicable models: Hardtop & Canvas Top...
  • Page 4 INTRODUCTION CLUTCH MANUAL TRANSMISSION AUTOMATIC TRANSMISSION TRANSFER PROPELLER SHAFT SUSPENSION AND AXLE BRAKE SYSTEM BODY ELECTRICAL SYSTEM AIR CONDITIONING SYSTEM ELECTRICAL WIRING DIAGRAMS...
  • Page 5 IN-1 INTRODUCTION HOW TO USE THIS MANUAL IN-2 IDENTIFICATION INFORMATION IN-5 GENERAL REPAIR INSTRUCTIONS IN-6 PRECAUTION IN-9 VEHICLE LIFT AND SUPPORT LOCATIONS •• IN-16 Hardtop & Canvas Top IN-16 Station Wagon IN-18 ABBREVIATIONS USED IN THIS MANUAL ••• IN-1 9 STANDARD BOLT TORQUE SPECIFICATIONS IN-20...

  • Page 6: How To Use This Manual

    IN-2 INTRODUCTION - HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN002-09 INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page.

  • Page 7: How To Use This Manual In

    IN-3 INTRODUCTION - HOW TO USE THIS MANUAL The procedures are presented in a step —by —step format: • The illustration shows what to do and where to do it. • The task heading tells what to do. • The detailed text tells how to perform the task and gives other information such as specifications and warnings.
  • Page 8 IN-4 INTRODUCTION - HOW TO USE THIS MANUAL CAUTIONS, NOTICES, HINTS: • CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. • NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired.

  • Page 9: Identification Information

    IN-5 INTRODUCTION - IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the outer sur- face of the front right side frame. This number is also stamped on the manufacturer's name plate. A: Vehicle Identification Number Manufacturer's Name Plate ENGINE SERIAL NUMBER The engine serial number is stamped on the right side of the...

  • Page 10: General Repair Instructions

    IN-6 INTRODUCTION - GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS INOO5-09 Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following: Before performing electrical work, disconnect the negative cable from the battery terminal.
  • Page 11 IN-7 INTRODUCTION - GENERAL REPAIR INSTRUCTIONS When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. Precoated parts are indicated in the component illustrations by the "^k"...
  • Page 12 IN-8 INTRODUCTION - GENERAL REPAIR INSTRUCTIONS 11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See pages IN —16 to 18). If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety.
  • Page 13 IN-9 INTRODUCTION - PRECAUTION PRECAUTION moo*-01 FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. Use only unleaded gasoline.
  • Page 14 INTRODUCTION - PRECAUTION WHEN SERVICING FULL-TIME 4WD VEHICLES The full —time 4WD Land Cruiser Station Wagon is equipped with the mechanical lock type center dif- ferential system. When carrying out any kind of ser- vicing or testing on a full —time 4WD in which the front or rear wheels are made to rotate (braking test, speedometer test, on —vehicle wheel balancing, etc.),...
  • Page 15 IN-11 INTRODUCTION - PRECAUTION HINT: • (w/o ABS) Move the vehicle backward or forward slightly if the indicator light does not operate correctly when the center differential lock switch is turned ON or OFF. • When the transfer select lever is put in "L" posi- tion, the center differential is put in LOCK con- dition regardless of the position of the center differential lock switch.
  • Page 16 IIM-12 INTRODUCTION - PRECAUTION LOCK Position Center Differential Transfer Lock Select Wheel Control Indicator Lever Switch Light A lifted wheel cannot be ro- tated if only one wheel is lifted up, even if transmission is in N range. Braking Force Test (Vehicle Speed: Below 0.5 k m / h or 0.3 mph) When performing low —...

  • Page 17: Precaution In

    IN-13 INTRODUCTION - PRECAUTION Speedometer Test or Other Tests (Using Speedometer Tester or Chassis Dynamometer) (w/o ABS) Remove the front propeller shaft, put the center differential in LOCK position, then put the rear wheels on the tester roller and perform the test. (w/ABS) Shift the transfer select lever to H position, jack up the front wheels, then put the rear wheels on...
  • Page 18 IN-14 INTRODUCTION - PRECAUTION (1) All four wheels should be jacked up, clearing the ground completely. (w/o ABS) The center differential should be in the LOCK po- sition with the transfer gear in H position. (w/ABS) Shift the transfer select lever to H position. (4) The parking brake lever should be fully released.
  • Page 19 IN-15 INTRODUCTION - PRECAUTION WHEN TOWING FULL-TIME 4WD VEHICLES Use one of the methods shown below to tow the vehicle. When there is trouble with the chassis and drive train, use method (flat bed truck) or method (2) (sling type tow truck with dollies) Recommended Methods: Emergency Method: (w/o ABS)
  • Page 20 INTRODUCTION - VEHICLE LIFT AND SUPPORT LOCATIONS IN 16 (Hardtop & Canvas Top) VEHICLE LIFT AND SUPPORT LOCATIONS (Hardtop & Canvas Top)
  • Page 21 INTRODUCTION - VEHICLE LIFT AND SUPPORT LOCATIONS IN-17 (Hardtop & Canvas Top)
  • Page 22 IIM-18 INTRODUCTION - VEHICLE LIFT AND SUPPORT LOCATIONS (Station Wagon) VEHICLE LIFT AND SUPPORT LOCATIONS (Station Wagon)
  • Page 23 IN-19 INTRODUCTION - ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Anti-Lock Brake System Air Conditioner Automatic Transmission Circuit Breaker Cruise Control System Compact Disc Electronic Control Unit Electronic Fuel Injection Emergency Locking Retractor Except FIPG Formed on Place Gasket Fusible Link Ignition Light Emitting Diode...
  • Page 24 IN-20 INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH...
  • Page 25 IN-21 INTRODUCTION - STANDARD BOLT TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS...
  • Page 26 Land Cruiser (Station RM184E Wagon) Chassis and Body Repair Manual RM290E Land Cruiser (Hardtop, Can- vas Top and Station Wagon) Chassis and Body Repair Manual Supplement NOTE: The following pages contain only the points which differ from the above listed manuals.

  • Page 27: Clutch Master Cylinder

    CL-2 CLUTCH (STATION WAGON) - CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER COMPONENTS 1FZ-FE Engine Filler Cap Float Grommet Reservoir Tank Clip Master Cylinder Body Clevis Piston Stop Plate Gasket Push Rod Slotted Spring Piston Spring Clutch Accumulator Specified torque Non-reusable part CLUTCH MASTER CYLINDER REMOVAL REMOVE MASTER CYLINDER Draw out fluid with syringe.
  • Page 28 CLUTCH (STATION WAGON) - CLUTCH MASTER CYLINDER MASTER CYLINDER DISASSEMBLY REMOVE RESERVOIR TANK Using a pin punch and a hammer, drive out the slotted spr- ing pin. Remove reservoir tank and grommet. REMOVE PUSH ROD Using a pin punch, loosen the staked part of the plate. Remove the piston stop plate, gasket and the push rod.
  • Page 29 " CLUTCH (STATION WAGON) - CLUTCH MASTER CYLINDER INSTALL RESERVOIR TANK Install reservoir tank and new grommet. Using a pin punch and a hammer, drive in the slotted spr- ing pin. MASTER CYLINDER INSTALLATION INSTALL MASTER CYLINDER Install the mounting nut, and torque them. Torque: 7.8 Nm (80 kgfcm, 69 in.

  • Page 30: Table Of Contents

    MT-1 MANUAL TRANSMISSION REFER TO FOLLOWING REPAIR MANUALS: NOTE: The following pages contain only the points which differ from the above listed manu- als. (HARDTOP & CANVAS TOP) DESCRIPTION MT-2 PREPARATION MT-3 TRANSMISSION REMOVAL AND INSTALLATION MT-4 OUTPUTSHAFT MT-13 SERVICE SPECIFICATIONS MT-24 (STATION WAGON) DESCRIPTION...

  • Page 31: Description

    MT-2 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - DESCRIPTION DESCRIPTION PRECAUTIONS When working with FIPG material, you must be observe the following. • Using a razor blade and gasket scraper, remove all the old sealant (FIPG) material from the gasket surfaces.

  • Page 32: Preparation

    MT-3 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) Transmission & Transfer Bearing Replacer Replacer Pipe Rear Axle Hub Guide Tool Output shaft rear ball bearing Differential Drive Pinion Bearing Replacer Bearing Remover...

  • Page 33: Installation

    MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) TRANSMISSION REMOVAL MT-4 AND INSTALLATION TRANSMISSION REMOVAL AND INSTALLATION COMPONENTS Shift Lever Knob Shift Lever Knob Shift Lever boot Release Cylinder Shift Lever boot Transfer Transmission Shift Lever Shift Lever Washer Tank Bracket Rear Propeller Shaft Transmission with Transfer Front Propeller Shaft...
  • Page 34 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) TRANSMISSION REMOVAL MT-5 AND INSTALLATION TRANSMISSION REMOVAL DISCONNECT BATTERY CABLE FROM NEGATIVE TER- MINAL REMOVE TRANSMISSION SHIFT LEVER FROM INSIDE OF VEHICLE Remove the transmission shift lever knob. Remove the four screws and remove the shift lever boot retainer.
  • Page 35 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) TRANSMISSION REMOVAL MT-6 AND INSTALLATION DISCONNECT FRONT AND REAR PROPELLER SHAFT FLANGES FROM COMPANION FLANGE ON TRANSFER Put matchmarks on the flange. Remove the four nuts. Remove the propeller shaft. REMOVE SPEEDOMETER CABLE Using pliers, remove the speedometer cable. 10.
  • Page 36 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) TRANSMISSION REMOVAL MT-7 AND INSTALLATION Remove the exhaust pipe clamp from the bracket. Remove the two bolts and exhaust pipe bracket from the clutch housing. 14. REMOVE STABILIZER BRAKET SET BOLTS Remove four stabilizer bracket set bolts. 15.
  • Page 37 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) TRANSMISSION REMOVAL MT-8 AND INSTALLATION 18. REMOVE ENGINE REAR MOUNTING Remove the four bolts and engine rear mounting from the transmission. 19. REMOVE TRANSFER FROM TRANSMISSION Remove the transfer adaptor rear mounting bolts. (b) Pull the transfer straight up and remove it from the trans- mission.
  • Page 38 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) TRANSMISSION REMOVAL MT-9 AND INSTALLATION TRANSMISSION INSTALLATION (See page MT-4) INSTALL TRANSFER TO TRANSMISSION (a) Apply MP grease to the adaptor oil seal. Install the transfer to the transmission. HINT: Take care not to damage the oil seal by the input gear spline when installing the transfer.
  • Page 39 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) TRANSMISSION REMOVAL MT-10 AND INSTALLATION INSTALL STABILIZER BRACKET SET BOLTS Install the stabirizer bracket with four bolts. Torque: 28 Nm (290 kgfcm, 21 ftlbf) INSTALL FRONT EXHAUST PIPE Install the exhaust pipe bracket and two bolts to the clutch housing.
  • Page 40 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) TRANSMISSION REMOVAL MT-11 AND INSTALLATION INSTALL SPEEDOMETER CABLE Using pliers, install the speedometer cable. 10. CONNECT BACK-UP LIGHT SWITCH CONNECTOR 1 1 . CONNECT PROPELLER SHAFT FLANGE TO COMPANION FLANGE ON TRANSFER Align the matchmarks on the flanges and connect the flanges with four nuts.
  • Page 41 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) TRANSMISSION REMOVAL MT-12 AND INSTALLATION 14. FILL TRANSMISSION WITH GEAR OIL Oil grade: API GL - 4 or GL - 5 Viscosity: SAE 75W - 90 Capacity: 2.7 liters (2.6 US qts, 3.1 Imp.qts) 15.

  • Page 42: Outputshaft

    MT-13 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT OUTPUT SHAFT COMPONENTS...

  • Page 43: In002

    MT-14 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT OUTPUT SHAFT DISASSEMBLY INSPECT EACH GEAR THRUST CLEARANCE Measure the thrust clearance of each gear. Standard clearance: 1st and 3rd gear 0.1 — 0.45 mm (0.0039 - 0.0177 in.) 2nd and 5th gear 0.1 —...
  • Page 44 MT-15 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT REMOVE HUB SLEEVE NO.1 ASSEMBLY, SYNCHRO- NIZER RING, SECOND GEAR AND NEEDLE ROLLER BEARING Using two screwdrivers and a hammer, drive out the snap ring. Using a press, remove the hub sleeve No.1 assembly, synchronizer rings, and second gear.
  • Page 45 MT-16 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT Using SST and a press, remove the hub sleeve No.2 as- sembly, synchronizer ring and third gear. SST 09555-55010 Remove the needle roller bearing. REMOVE HUB SLEEVE NO.2, SHIFTING KEYS AND SPRINGS FROM CLUTCH HUB NO.2 Using a screwdriver, remove the three shifting keys and t w o springs from the clutch hub No.2.
  • Page 46 MT-17 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT OUTPUT SHAFT ASSEMBLY INSPECTION INSPECT OUTPUT SHAFT Using calipers, measure the output shaft flange thick- ness. Minimum thickness: 4.725 mm (0.1860 in.) If the thickness is less than the minimum, replace the output shaft.
  • Page 47 MT-18 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end. Minimum clearance: 1st gear 1.1 mm (0.0433 in.) 3rd gear 0.8 mm (0.0315 in.) HINT: •...
  • Page 48 MT-19 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT OUTPUT SHAFT ASSEMBLY INSTALL CLUTCH HUB NO.1, NO.2 AND NO.3 INTO HUB SLEEVE Install the clutch hub and shifting keys to the hub sleeve. Install the springs under the shifting keys. NOTICE: Install the key springs positioned so that their end gaps are not in line.
  • Page 49 MT-20 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT Using a brass bar and hammer, drive in the snap ring. INSPECT FIFTH GEAR THRUST CLEARANCE Using a feeler gauge, measure the fifth gear thrust clear- ance. Standard clearance: 0.1 - 0.35 mm (0.0039 - 0.0138 in.) INSTALL THIRD GEAR AND HUB SLEEVE NO.2 ASSEM- Apply gear oil to the shaft and needle roller bearing.
  • Page 50 MT-21 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT Using a brass bar and hammer, drive in a new snap ring. INSPECT THIRD GEAR THRUST CLEARANCE Using a feeler gauge, measure the third gear thrust clear- ance. Standard clearance: 0.1 - 0.45 mm (0.0039 - 0.0138 in.) INSTALL SECOND GEAR AND HUB SLEEVE NO.1 AS- SEMBLY...
  • Page 51 MT-22 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT Using a brass bar and hammer, drive in a new snap ring. 10. INSPECT SECOND GEAR THRUST CLEARANCE Using a feeler gauge, measure the second gear thrust clearance. Standard clearance: 0.1 - 0.35 mm (0.0039 - 0.0138 in.) 11.
  • Page 52 MT-23 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - OUTPUT SHAFT Install the pin and thrust washer. 13. INSTALL SNAP RING Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, drive in a new snap ring.

  • Page 53: Service Specifications

    MT-24 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA...
  • Page 54 MT-25 MANUAL TRANSMISSION (HARDTOP & CANVAS TOP) - SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS...
  • Page 55 MT-26 MANUAL TRANSMISSION (STATION WAGON) - DESCRIPTION DESCRIPTION PRECAUTIONS When working with FIPG material, you must be observe the following. • Using a razor blade and gasket scraper, remove all the old sealant (FIPG) material from the gasket surfaces. • Throughly clean all components to remove all the loose material. •...
  • Page 56 MT-27 MANUAL TRANSMISSION (STATION WAGON) - PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09316-60010 Transmission & Transfer Bearing Replacer (09316-00010) Replacer Pipe 09523-36010 Rear Axle Hub Guide Tool Output shaft rear ball bearing 09555-55010 Differential Drive Pinion Bearing Replacer 09950-00020 Bearing Remover...
  • Page 57 MT-28 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT OUTPUT SHAFT COMPONENTS...
  • Page 58 MT-29 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT...
  • Page 59 MT-30 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT OUTPUT SHAFT DISASSEMBLY INSPECT EACH GEAR THRUST CLEARANCE Measure the thrust clearance of each gear. Standard clearance: 1st and 3rd gear 0.1 — 0.45 mm (0.0039 - 0.0177 in.) 2nd and 5th gear 0.1 —...
  • Page 60 MT-31 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT REMOVE HUB SLEEVE NO.1 ASSEMBLY, SYNCHRO- NIZER RING. SECOND GEAR AND NEEDLE ROLLER BEARING Using t w o screwdrivers and a hammer, drive out the snap ring. Using a press, remove the hub sleeve No.1 assembly, synchronizer rings, and second gear.
  • Page 61 MT-32 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT Using SST and a press, remove the hub sleeve No.2 as- sembly, synchronizer ring and third gear. H15OF — Single Synchronizer ring H151F — Triple Synchronizer rings SST 09555-55010 Remove the needle roller bearing. REMOVE HUB SLEEVE NO.2, SHIFTING KEYS AND SPRINGS FROM CLUTCH HUB NO.2 Using a screwdriver, remove the three shifting keys and...
  • Page 62 MT-33 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT OUTPUT SHAFT ASSEMBLY INSPECTION INSPECT OUTPUT SHAFT Using calipers, measure the output shaft flange thick- ness. Minimum thickness: 4.725 mm (0.1860 in.) If the thickness is less than the minimum, replace the output shaft.
  • Page 63 MT-34 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end. Minimum clearance: 1st gear 1.1 mm (0.0433 in.) 3rd and 5th gear 0.8 mm (0.0315 in.) HINT: •...
  • Page 64 MT-35 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT OUTPUT SHAFT ASSEMBLY INSTALL CLUTCH HUB NO.1, NO.2 AND NO.3 INTO HUB SLEEVE Install the clutch hub and shifting keys to the hub sleeve. Install the springs under the shifting keys. NOTICE: Install the key springs positioned so that their end gaps are not in line.
  • Page 65 MT-36 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT Using a brass bar and hammer, drive in the snap ring. INSPECT FIFTH GEAR THRUST CLEARANCE Using a feeler gauge, measure the fifth gear thrust clear- ance. Standard clearance: 0.1 - 0.35 mm (0.0039 - 0.0138 in.) INSTALL THIRD GEAR AND HUB SLEEVE NO.2 ASSEM- (H151F) Place the synchronizer rings on the 3rd gear.
  • Page 66 MT-37 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT INSTALL SNAP RING Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, drive in a new snap ring. MEASURE THIRD GEAR THRUST CLEARANCE Using a feeler gauge, measure the third gear thrust clear- ance.
  • Page 67 MT-38 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT (b) Using a brass bar and a hammer, drive in a new snap ring. 10. INSPECT SECOND GEAR THRUST CLEARANCE Using a feeler gauge, measure the second gear thrust clearance. Standard clearance: 0.1 - 0.35 mm (0.0039 - 0.0138 in.) 11.
  • Page 68 MT-39 MANUAL TRANSMISSION (STATION WAGON) - OUTPUT SHAFT Using SST and a press, install the ball bearing. SST 09316-60010 (09316-00010), 09523-36010 Install the pin and thrust washer. 13. INSTALL SNAP RING Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, drive in a new snap ring.
  • Page 69 MT-40 MANUAL TRANSMISSION (STATION WAGON) - SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA...
  • Page 70 MT-41 MANUAL TRANSMISSION (STATION WAGON) - SERVICE SPECIFICATIONS...

  • Page 71: Table Of Contents

    AT-1 AUTOMATIC TRANSMISSION REFER TO LAND CRUISER (STATION WAGON) REPAIR MANUAL FOR CHASSIS AND BODY (Pub. No. RM184E) NOTE: The following pages contain only the points which differ from the above listed man- ual. (STATION WAGON) DESCRIPTION AT-2 OPERATION AT-4...
  • Page 72 AT-2 AUTOMATIC TRANSMISSION (STATION WAGON) - DESCRIPTION DESCRIPTION GENERAL DESCRIPTION The A442F automatic transmission is a four-speed automatic transmission with a four-speed transfer, developed with the aim of producing an easy-driving 4WD vehicle. A lock-up mechanism is built into the torque converter. The A442F transmission is mainly composed of the torque converter, the overdrive (hereafter called O/D) planetary gear unit, 3-speed planetary gear unit, 4-speed transfer, hydraulic control system and an electronic control system.
  • Page 73 AT-3 AUTOMATIC TRANSMISSION (STATION WAGON) - DESCRIPTION GENERAL SPECIFICATIONS...

  • Page 74: Operation

    AT-4 AUTOMATIC TRANSMISSION (STATION WAGON) - OPERATION OPERATION OPERATION...
  • Page 75 AT-5 AUTOMATIC TRANSMISSION (STATION WAGON) - OPERATION FUNCTION OF COMPONENTS...
  • Page 76 AT-6 AUTOMATIC TRANSMISSION (STATION WAGON) - OPERATION The conditions of operation for each gear position are shown on the following illustration:...
  • Page 77 AT-7 AUTOMATIC TRANSMISSION (STATION WAGON) - OPERATION...
  • Page 78 AT-8 AUTOMATIC TRANSMISSION (STATION WAGON) - OPERATION HYDRAULIC CONTROL SYSTEM The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accumulators, the clutches and brakes, as well as the fluid passages which connect all of these com- ponents.
  • Page 79 AT-9 AUTOMATIC TRANSMISSION (STATION WAGON) - OPERATION ELECTRONIC CONTROL SYSTEM The electronic control system for the A442F automatic transmission provide extremely precise control of the gear shift timing and lock-up timing in response to driving conditions as sensed by various sen- sors located throughout the vehicle and in response to the engine's running condition.
  • Page 80 AT-10 AUTOMATIC TRANSMISSION (STATION WAGON) - OPERATION FUNCTION OF TCM • Control of Shift Timing The ECU has programmed into its memory the optimum shift pattern for each shift lever position (D, 2, L ranges) and driving mode (Normal or Power). Based on the appropriate shift pattern, the ECU turns No.1, No.2 and timing solenoid valves on or off in accordance with the vehicle speed signal from the speed sensor and the throttle opening signal from the throttle position sensor.
  • Page 81 AT-11 AUTOMATIC TRANSMISSION (STATION WAGON) - OPERATION A/T. FLUID TEMPERATURE WARNING SYSTEM The ECT ECU detects the A/T fluid temperature by means of a fluid temperature sensor fitted to the union. The A/T fluid may become extremely when the vehicle is under and extreme load, as when driv- ing on sand or climbing uphill.
  • Page 82 AT-12 AUTOMATIC TRANSMISSION (STATION WAGON) - PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) EQUIPMENT...
  • Page 83 AT-13 AUTOMATIC TRANSMISSION (STATION WAGON) - PERPARATION LUBRICANT SSM (SPECIAL SERVICE MATERIALS)

  • Page 84: Troubleshooting

    AT-14 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING TROUBLESHOOTING Trouble occurring in the ECT can stem from one of three sources: the engine, the ECT electronic con- trol unit or the transmission itself. Before troubleshooting, determine in which these three sources the problem lies, and begin troubleshooting with the simplest operation, gradually working up in order or difficulty.
  • Page 85 AT-15 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING NOTICE: Refer to A442F Automatic Transmission Repair Manual (Pub. No. RM314E) when mark appears in the column for page numbers.
  • Page 86 AT-16 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING NOTICE: Refer to A442F Automatic Transmission Repair Manual (Pub. No. RM314E) when mark appears in the column for page numbers.
  • Page 87 AT-17 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING DIAGNOSIS SYSTEM DESCRIPTION A self-diagnosis function is built into the electrical control system. Warning is indicated by the overdrive OFF indica- tor light. HINT: Warning and diagnostic codes can be read only when the overdrive switch is ON. If OFF, the overdrive OFF light is lit continuously and will not blink.
  • Page 88 AT-18 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING READ DIAGNOSTIC CODE TURN IGNITION SWITCH AND O/D SWITCH TO ON Do not start the engine. HINT: Warning and diagnostic codes can be read only when the overdrive switch is ON. If OFF, the overdrive OFF light willl light continuously and will not blink.
  • Page 89 AT-19 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING DIAGNOSTIC CODES...
  • Page 90 AT-20 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING CANCEL OUT DIAGNOSTIC CODE After repair of the trouble area, the diagnostic code re- tained in memory by the ECT ECU must be canceled by removing the DOME fuse (10 A) for 10 seconds or more, depending on ambient temperature (the lower the term- perature, the longer the fuse must be left out) with the ig- nition switch OFF.
  • Page 91 AT-21 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING TROUBLESHOOTING FLOW-CHART HINT: • If diagnostic code Nos.41, 42, 61, 62, 63, 64, 65, 86, 88 (1FZ-FE engine only) and are output, the overdrive OFF indicator light will begin to blink immediately to warn the driver. However, an impact or shock may cause the blinking to stop;...
  • Page 92 AT-22 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING Diagnostic Code 61 (No.2 speed sensor circuitry)
  • Page 93 AT-23 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING Diagnostic Code 64 (Lock-up solenoid valve circuitry)
  • Page 94 AT-24 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING Diagnostic Code 86 (Engine speed sensor circuitry) (1HD-T engine)
  • Page 95 AT-25 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING PRELIMINARY CHECK CHECK FLUID LEVEL HINT: • The vehicle must have driven so that the engine and transmission are at normal operating temperature. (Fluid temperature: 70 - 80°C or 1 58 - 176°F) •...
  • Page 96 AT-26 AUTOMATIC TRANSMISSION (STATION WAGON) TROUBLESHOOTING Check the fluid level with the normal operating tempera- ture (70 — 80°C or 158 — 176°F) and add as neces- sary. NOTICE: Do not overfill. INSPECT THROTTLE CABLE Check that the throttle cable is installed correctly and not bent.
  • Page 97 AT-27 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING INSPECT NEUTRAL START SWTICH Check that the engine can be started with the shift lever only in the N or P range, but not in other ranges. If not as started above, carry out the following adjust- ment procedures.
  • Page 98 AT-28 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING MANUAL SHIFTING TEST HINT: With this test, it can be determine whether the trouble lies within the electrical circuit or is a mechanical problem in the transmission. DISCONNECT SOLENOID WIRE INSPECT MANUAL DRIVING OPERATION Check that the shift and gear position correspond with the table below.
  • Page 99 AT-29 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING ELECTRONIC CONTROL SYSTEM PRECAUTION Do not open the cover or the case of the TCM and vari- ous computer unless absolutely necessary. (If the IC ter- minals are touched, the IC may be destroyed by static electricity.) ELECTRONIC CONTROL CIRCUIT...
  • Page 100 AT-30 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING...
  • Page 101 AT-31 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING ELECTRONIC CONTROL COMPONENTS...
  • Page 102 AT-32 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING TROUBLESHOOTING FLOW - CHART Trouble No. 1 No Shifting...
  • Page 103 AT-33 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING Trouble No.2 Shift point too high or too low...
  • Page 104 AT-34 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING Trouble No.3 No up-shift to overdrive (After warm-up)
  • Page 105 AT-35 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING Trouble No.4 No lock-up (After warm-up)
  • Page 106 AT-36 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING TERMINAL VOLTAGE INSPECTION INSPECT THROTTLE POSITION SENSOR SIGNAL Turn the ignition switch to ON. Do not start the engine. Connect a voltmeter to check connector terminals T While slowly depressing the accelerator pedal, check that terminal voltage rises in sequence.
  • Page 107 AT-37 AUTOMATIC TRANSMISSION (STATION WAGON) TROUBLESHOOTING ELECTRONIC CONTROL COMPONENETS INSPECTION INSPECT VOLTAGE OF ECT ECU Turn on the ignition switch. Measure the voltage at each terminal.
  • Page 108 AT-38 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING...
  • Page 109 AT-39 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING INSPECT SOLENOID Disconnect the connector from ECT ECU. Measure the resistance between ground. Resistance: 11-15 Apply battery voltage to each terminal. Check that an op- eration noise can be heard from the solenoid.
  • Page 110 AT-40 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING CHECK SOLENOID SEALS If there is foreign material in the solenoid valve, there will be no fluid control even with sloenoid operation. (a) Check No.1, No.2 and timing solenoid valves. • Check that the solenoid valves do not leak when low- pressure compressed air is applied.
  • Page 111 AT-41 AUTOMATIC TRANSMISSION (STATION WAGON) TROUBLESHOOTING INSPECT NO.2 SPEED SENSOR Jack up the rear wheel on one side. Connect an ohmmeter between the terminals. Spin the wheel and check that the meter needle defects from 0 to INSPECT NO.1 SPEED SENSOR (See page BE-10) INSPECT PATTERN SELECT SWITCH Using an ohmmeter, check the continuity of terminals for...
  • Page 112 AT-42 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING A/T FLUID TEMPERATURE WARNING SYSTEM CIRCUIT GAUGE Indicator Light MAIN To ALT (L) A/T Fluid Temperature Battery Sensor A/T Fluid Temperature Sensor Q03071 204059 g-1O-2-B 1H-1-2-A 11. INSPECT A/T FLUID TEMPERATURE WARNING LIGHT Disconnect the connector from the temperature sensor.
  • Page 113 AT-43 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING STALL TEST The objective of this test is to check the overall performance of the transmission and engine by mea- suring the stall speeds in the D and R ranges. NOTICE: • Perform the test at normal operating fluid temperature (50 — 80°C, or 122 — 176°F). •...
  • Page 114 AT-44 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING...
  • Page 115 AT-45 AUTOMATIC TRANSMISSION (STATION WAGON) TROUBLESHOOTING TIME LAG TEST When the shift lever is shifted while the engine is idling, there will be a certain time elapse or lag before the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch, direct clutch and first and reverse brake.
  • Page 116 AT-46 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING...
  • Page 117 AT-47 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING HYDRAULIC TEST PREPARATION Warm up the transmission fluid. Remove the transmission case test plug and connect the hydraulic pressure gauge. SST 09992-00094 (Oil pressure gauge) NOTICE: • Perform the test at normal operating fluid temperature (50 — 8 0 ° C or 122 — 176°F). •...
  • Page 118 AT-48 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING EVALUATION If the measured values at all positions are higher than specified: • Throttle cable out of adjustment • Throttle valve defective • Regulator valve defective (b) If the measured values at all positions are lower than specified: •...

  • Page 119: Road Test

    AT-49 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING ROAD TEST NOTICE: Perform the test at normal operating fluid tem- perature (50 - 80°C or 122 - 176°F). D RANGE TEST IN NORM AND PWR PATTERN RANGES Shift into the D range and hold the accelerator pedal con- stant at the full throttle valve opening position.
  • Page 120 AT-50 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING (c) Run at the D Range lock-up or O/D gear and check for ab- normal noise and vibration. HINT: The check for the cause of abnormal noise and vibration must be made with extreme care as it could also be due to loss of balance in the propeller shaft, differen- tial, torque converter, etc.
  • Page 121 AT-51 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING Check for abnormal noise at acceleration and decelera- tion, and for shock at up-shift and down-shift. L RANGE TEST (a) While running in the L range, check to see that there is no up-shift to 2nd gear.
  • Page 122 AT-52 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING P RANGE TEST Stop the vehicle on a gradient (more than 5°) and after shifting into the P range, release the parking brake. Then check to see that the parking lock pawl holds the vehicle in place.
  • Page 123 AT-53 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING AUTOMATIC SHIFT SCHEDULE Engine: 1FZ-FE Tire size: 7.50R16-6 km/h (mph) Engine: 1FZ-FE Tire size: 215/80-R16 km/h (mph)
  • Page 124 AT-54 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING Engine: 1FZ-FE Tire size: 275/70-R16 km/h (mph) Engine: 1HD-T Tire size: 7.50R16-6 km/h (mph) Engine: 1HD-T Tire size: 245/85-R16 km/h (mph)
  • Page 125 AT-55 AUTOMATIC TRANSMISSION {STATION WAGON) - TROUBLESHOOTING Engine: 1HD-T Tire size: 215/80-R16 km/h (mph) Engine: 1HD-T Tire size: 275/70-R16 km/h (mph)
  • Page 126 AT-56 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING TROUBLESHOOTING MATRIX CHART You will find the troubles easier using the table will shown below. In this table, each number shows the priority of cause in troubles. Check each part in order. If necessary, replace these parts. (ON - VEHICLE)
  • Page 127 AT-57 AUTOMATIC TRANSMISSION (STATION WAGON) - TROUBLESHOOTING (OFF - VEHICLE) See Page Parts Name Trouble Remark : Refer to A442F Automatic Transmission Repair Manual. (Pub. No. RM314E)

  • Page 128: Valve Body

    AT-58 AUTOMATIC TRANSMISSION (STATION WAGON) - VALVE BODY VALVE BODY VALVE BODY REMOVAL REMOVE TRANSMISSION AND TRANSFER UNDER COVER CLEAN TRANSMISSION EXTERIOR To prevent contamination, clean the exterior transmis- sion. DRAIN TRANSMISSION FLUID Remove the drain plug and drain fluid into a suitable con- tainer.
  • Page 129 AT-59 AUTOMATIC TRANSMISSION (STATION WAGON) - VALVE BODY REMOVE OIL STRAINER Remove the four bolts and oil strainer. REMOVE VALVE BODY (a) Remove the twenty-one bolts. Disconnect the four connectors from the solenoids. (c) Remove the throttle cable the cam and remove the valve body.
  • Page 130 AT-60 AUTOMATIC TRANSMISSION (STATION WAGON) - VALVE BODY (b) Connect the throttle cable to the cam. Install the other bolts. HINT: Each bolt length is indicated below. Bolt length: A 41 mm (1.61 in.) B 45 mm (1.77 in.) C 22 mm (0.87 in.) D 32 mm (1.26 in.) E 28 mm (1.10 in.) F 52 mm (2.05 in.)
  • Page 131 AT-61 AUTOMATIC TRANSMISSION (STATION WAGON) - VALVE BODY INSTALL MAGNETS IN PAN Install the two magnets in the oil pan as shown in the il- lustration. INSTALL OIL PAN Remove any packing material and be careful not to drop oil on the contacting surface of the transmission case and oil pan.
  • Page 132 AT-62 AUTOMATIC TRANSMISSION (STATION WAGON) - VALVE BODY FILL TRANSMISSION WITH ATF Capacity: 6.0 liters (6.3 US qts, 5.3 Imp.qts) NOTICE: Do not overfill. Fluid type: ATF DEXRON® II 10. CHECK FLUID LEVEL (See page AT-25)

  • Page 133: Throttle Cable

    AT-63 AUTOMATIC TRANSMISSION (STATION WAGON) - THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE REMOVAL REMOVE FRONT PROPELLER SHAFT (See Pub No. RM184E, page PR-3) DISCONNECT THROTTLE CABLE Disconnect the cable housing from the bracket. Disconnect the cable from the throttle linkage. Disconnect the cable from the torque converter housing.
  • Page 134 AT-64 AUTOMATIC TRANSMISSION (STATION WAGON) - THROTTLE CABLE THROTTLE CABLE INSTALLATION INSTALL CABLE IN TRANSMISSION CASE Coat a new O-ring with ATF, and install it to the cable. Install the cable to the transmission case. INSTALL THROTTLE CABLE CLAMP TO TRANSMISSION HOUSING INSTALL FRAME CROSSMEMBER SET BOLTS Torque:...
  • Page 135 AT-65 AUTOMATIC TRANSMISSION (STATION WAGON) - THROTTLE CABLE ADJUST THROTTLE CABLE (See page AT-26) 10. FILL TRANSMISSION WITH ATF Capacity: 6.0 liters (6.3 US qts, 5.3 Imp.qts) NOTICE: Do not overfill. Fluid type: ATF DEXRON® H 1 1 . CHECK FLUID LEVEL (See page AT-25)
  • Page 136 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-66 AND INSTALLATION ASSEMBLY REMOVEAL AND INSTALLATION COMPONENTS Hold Down Clamp Cover Battery Fan Shroud Starter Oil Cooler Pipe Level Gauge Oil Filler Tube Wire Harness Vacuum Hose Shift Control Rod (1HD-T Only) Shiffener Plate Speedometer Cable ("IHD-T Only) Transfer Under...
  • Page 137 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-67 AND INSTALLATION TRANSMISSION REMOVAL DISCONNECT BATTERY CABLE FROM NEGATIVE TER- MINAL REMOVE BATTERY AND COVER LOOSEN FAN SHROUD OF COOLING FAN TO AVOID DAMAGE TO FAN...
  • Page 138 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-68 AND INSTALLATION DISCONNECT THROTTLE CABLE Loosen the adjusting nut and disconnect the cable hous- ing from the bracket. Disconnect the cable from the linkage. (1HD-T) REMOVE STARTER MOUNTING BOLT REMOVE TRANSMISSION SELECT LEVER AND TRANS- FER SHIFT LEVER Remove the clip, washer and wave washer, and discon- nect the link.
  • Page 139 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-69 AND INSTALLATION Remove the transfer shift lever knob. Remove the four screws and the console. Remove the four bolts and transfer shift lever bolt. Remove the three bolts and the console box. Remove the six bolts and the transmission shift lever as- sembly.
  • Page 140 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-70 AND INSTALLATION REMOVE NO.1 SPEED SENSOR CONNECTOR REMOVE FRONT AND REAR PROPELLER SHAFTS (See Pub. No. RM184E, page PR-3) (w/ MECHAICAL WINCH) REMOVE POWER TAKE OF SHIFT CABLE Pull out the pin and disconnect the cable. Remove the t w o bolts and the cable bracket.
  • Page 141 ASSEMBLY REMOVAL AUTOMATIC TRANSMISSION (STATION WAGON) AT-71 AND INSTALLATION Remove the bolt and the filler tube. 11. DISCONNECT TWO OIL COOLER TUBES (a) Remove the bolt and clamp. Disconnect the temperature sensor connector. Disconnect the two oil cooler tubes.
  • Page 142 ASSEMBLY REMOVAL AUTOMATIC TRANSMISSION (STATION WAGON) AT-72 AND INSTALLATION 12. REMOVE ENGINE UNDER COVER Remove the four bolts and the cover. 13. DISCONNECT NO.2 SPEED SENSOR CONNECTOR 14. DISCONNECT SOLENOID CONNECTOR 15. REMOVE SIX TORQUE CONVERTER MOUNTING BOLTS Remove the converter hole plug.
  • Page 143 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-73 AND INSTALLATION (b) Turn the crankshaft to gain access to each bolt. Remove the six bolt. 16. REMOVE CROSSMEMBER (a) Support the transmission with the transmission jack. (b) Remove the eight bolts and then remove the frame cross- member.
  • Page 144 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-74 AND INSTALLATION (1FZ-FE) Remove the nut and disconnect the connectors from the starter. (1FZ-FE) Remove the two bolts and the starter. Disconnect the neutral start switch connectors. Remove the bolt and disconnect the oil cooler tube clamp from the converter housing.
  • Page 145 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-75 AND INSTALLATION (m) Remove the bolts and the transmission.
  • Page 146 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-76 AND INSTALLATION TORQUE CONVERTER CLEANING If the transmission is contaminated, the torque converter and transmission cooler should be thoroughly flashed with ATF. TORQUE CONVERTER AND DRIVE PLATE INSPECTION INSPECT ONE-WAY CLUTCH Install SST in the inner race of one-way clutch. SST 09350-30020 (09351-32010) (b) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch.
  • Page 147 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-77 AND INSTALLATION MEASURE TORQUE CONVERTER SLEEVE RUNOUT Temporarily mount the torque converter to the drive plate. Set up a dial indicator. If runout exceeds 0.30 mm (0.0118 in.), try to correct by reorienting the installation of the converter. If excessive runout cannot be corrected, replace the torque converter.
  • Page 148 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-78 AND INSTALLATION (1HD-T) Install the left and right stiffener plates with the eight bolt. Torque: 37 Nm (380 kgf-cm, 27 ftlbf) Connect the oil cooler tube clamp to the converter hous- ing with the bolt. Connect the park/neutral position switch.
  • Page 149 ASSEMBLY REMOVAL AUTOMATIC TRANSMISSION (STATION WAGON) AT-79 AND INSTALLATION INSTAL CROSSMEMBER Install the crossmember with eight bolts and t w o nuts. Torque: 61 N-m (620 kgf-cm, 45 ft-lbf) INSTALL TORQUE CONVERTER MOUNTING BOLTS Install the six bolts while turning the crankshaft. Torque: 55 N-m (550 kgf-cm, 40 ft-lbf) Seal the converter hole plug with adhesive.
  • Page 150 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-80 AND INSTALLATION CONNECT SOLENOID CONNECTOR CONNECT NO.2 SPEED SENSOR CONNECTOR INSTALL ENGINE UNDER COVER Install the cover with the four bolts. Torque: 28 Nm (290 kgf-cm, 21 ftlbf) 10. CONNECT TWO OIL COOLER TUBES Connect the two oil cooler tubes.
  • Page 151 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-81 AND INSTALLATION Connect the oil temperature sensor connector. 11. REMOVE OIL FILLER TUBE Install the filler tubes with the bolt. Install the bolt. Install the level gauge. 12. (w/ MECHANICAL WINCH) INSTALL POWER TAKE-OFF DRIVE SHAFT (a) Align the matchmarks on the joint flange yoke and drive shaft.
  • Page 152 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-82 AND INSTALLATION Install the front and rear bracket. 13. (w/MECHANICAL WINCH) INSTALL POWER TAKE-OFF SHIFT CABLE Install the two bolts and the cable bracket. Connect the cable and insert the pin. 14. CONNECT NO.1 SPEED SENSOR CONNECTOR 15.
  • Page 153 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-83 AND INSTALLATION Install the console box with the three bolts. Install the transfer shift lever boot with the four bolts. Install the four screws and the console. Install the transfer shift lever knob. (g) Connect the link with the washer and nut.
  • Page 154 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-84 AND INSALLATION 17. (1HD-T) INSTALL STARTER MOUNT BOLT 18. CONNECT THROTTLE CABLE Connect the cable from the throttle linkage. Tighten the adjusting nuts and connect the cable housing to the bracket. 19. TIGHTEN FAN SHROUD OF COOLING FAN TO AVOID DAMAGE TO FAN 20.
  • Page 155 AUTOMATIC TRANSMISSION (STATION WAGON) ASSEMBLY REMOVAL AT-85 AND INSALLATION 24. CHECK FLUID LEVEL (See page AT-25)
  • Page 156 AT-86 AUTOMATIC TRANSMISSION (STATION WAGON) - SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATE km/h (mph) Shift point schedule...
  • Page 157 AT-87 AUTOMATIC TRANSMISSION (STATION WAGON) - SERVICE SPECIFICATIONS...
  • Page 158 AT-88 AUTOMATIC TRANSMISSION (STATION WAGON) - SERVICE SPECIFICATIONS TORQUE SPECIFICATION...
  • Page 159 TR-1 TRANSFER REFER TO LAND CRUISER (STATION WAGON) REPAIR MANUAL FOR CHASSIS AND BODY (Pub. No. RM184E) NOTE: The following pages contain only the points which differ from the above listed man- ual. (HF2AV FOR STATION WAGON WITH ABS) DESCRIPTION...

  • Page 160: Specifications

    TR-2 TRANSFER DESCRIPTION DESCRIPTION The transfer transmits the drive force from the transmission to the front and rear wheels. The specifications and cross-section diagrams are as shown. HF2AV TRANSFER V01733 Specifications...
  • Page 161 TR-3 TRANSFER - PRECAUTIONS, TROUBLESHOOTING PRECAUTIONS When working with FIPG material, you must be observe the following. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket sur- faces. • Thoroughly clean all components to remove all the loose material. •...
  • Page 162 TR-4 TRANSFER - COMPONENTS COMPONENTS...
  • Page 163 TR-5 TRANSFER - TRANSFER DISASSEMBLY TRANSFER DISASSEMBLY (See page TR-4) REMOVE BREATHER HOSE REMOVE MOTOR ACTUATOR Remove the four bolts and motor actuator. HINT: Remove the motor actuator in differential lock condition. REMOVE OUTPUT GEAR REMOVE SCREW PLUG, SPRING AND BALL Using a torx socket wrench, remove the screw plug.
  • Page 164 TR-6 TRANSFER - TRANSFER DISASSEMBLY REMOVE TRANSFER INDICATOR SWITCHES Remove the Center Diff Lock indicator switch, L4 posi- tion switch and neutral position switch. (w/o POWER TAKE-OFF) REMOVE POWER TAKE-OFF COVER Remove the ten bolts, power take-off cover and gasket. (w/ POWER TAKE-OFF) REMOVE POWER TAKE-OFF CASE Remove the ten bolts, power take-off case and gasket.
  • Page 165 TR-7 TRANSFER - TRANSFER DISASSEMBLY 10. SEPARATE SHIFT FORK NO.2 AND FORK SHAFT Using two screwdrivers and a hammer, tap out the three snap rings. Separate the shift fork No.2 and fork shaft. 1 1 . REMOVE REAR EXTENSION HOUSING Remove the nine bolts and rear extension housing.
  • Page 166 TR-8 TRANSFER - TRANSFER DISASSEMBLY 15. REMOVE CASE COVER Remove the five bolts. Using a brass bar and hammer, tap the case cover and re- move it. 16. SEPARATE FRONT CASE AND REAR CASE Using snap ring pliers, remove the snap ring. Remove the eight bolts.
  • Page 167 TR-9 TRANSFER - TRANSFER DISASSEMBLY 17. REMOVE TWO BEARING RACES FROM REAR CASE 18. REMOVE INPUT SHAFT ASSEMBLY Using a plastic hammer, remove the input shaft assem- bly. 19. REMOVE IDLE GEAR ASSEMBLY, CENTER DIFFEREN- TIAL ASSEMBLY AND HIGH AND LOW SHIFT FORK AS- SEMBLY 20.
  • Page 168 TR-10 TRANSFER - TRANSFER DISASSEMBLY (b) Using a brass bar, hammer and socket wrench, tap out the lever lock pin. Remove the shift outer lever and inner lever. 22. IF NECESSARY, REPLACE SHIFT LEVER OIL SEAL (a) Using a screwdriver, pry out the oil seal. (b) Using SST and a hammer, drive in a new oil seal.
  • Page 169 TR-11 TRANSFER - TRANSFER DISASSEMBLY (b) Using SST and a hammer, drive in a new oil seal. SST 09316-60010 (09316-00010, 09316-00030) 24. REMOVE OIL RECEIVER FROM FRONT CASE Remove the set bolt and oil receiver. 25. REMOVE TWO BEARING RACES FROM FRONT CASE Using SST, remove the bearing race.

  • Page 170: Component Parts

    TR-12 TRANSFER - COMPONENT PARTS (INPUT SHAFT ASSEMBLY) COMPONENT PARTS Input Shaft Assembly COMPONENTS DISASSEMBLY OF INPUT SHAFT ASSEMBLY REMOVE REAR BALL BEARING Using snap ring pliers, remove the snap ring. Using a press and socket wrench, remove the rear ball bearing.
  • Page 171 TR-13 TRANSFER - COMPONENT PARTS (INPUT SHAFT ASSEMBLY) (w/ POWER TAKE-OFF) REMOVE POWER TAKE-OFF DRIVE GEAR Using snap ring pliers, remove the snap ring. Using a press, remove the power take-off drive gear. REMOVE INPUT GEAR (w/o Power take-off) Using snap ring pliers, remove the snap ring. Using a press, remove the input gear.
  • Page 172 TR-14 TRANSFER - COMPONENT PARTS (INPUT SHAFT ASSEMBLY) ASSEMBLY OF INPUT SHAFT ASSEMBLY INSTALL FRONT BALL BEARING Using a press, install the front ball bearing. INSTALL INPUT GEAR (a) Using a press, install the input gear. (w/o Power take-off) Select a snap ring that will allow minimum axial play and install it on the shaft.
  • Page 173 TR-15 TRANSFER - COMPONENT PARTS (INPUT SHAFT ASSEMBLY) Select a snap ring that will allow minimum axial play and install it on the shaft. INSTALL REAR BALL BEARING Using SST and a press, install the rear ball bearing. SST 09316-60010 (09316-00030) Select a snap ring that will allow minimum axial play.
  • Page 174 TR-16 TRANSFER - COMPONENT PARTS (IDLER GEAR ASSEMBLY) Idler Gear Assembly COMPONENTS DISASSEMBLY OF IDLER GEAR ASSEMBLY CHECK OIL CLEARANCE AND THRUST CLEARANCE OF IDLER LOW GEAR (a) Using a feeler gauge, measure the idler low gear thrust clearance. Standard clearance: 0.125 —...
  • Page 175 TR-17 TRANSFER - COMPONENT PARTS (IDLER GEAR ASSEMBLY) REMOVE FRONT TAPER ROLLER BEARING Using SST, remove the front taper roller bearing. SST 09950-2001 7 REMOVE REAR TAPER ROLLER BEARING Using SST, press and socket wrench, remove the rear taper roller bearing. SST 09950-00020 REMOVE IDLER LOW GEAR AND NEEDLE ROLLER BEAR- REMOVE HIGH AND LOW CLUTCH SLEEVE...
  • Page 176 TR-18 TRANSFER - COMPONENT PARTS (IDLER GEAR ASSEMBLY) INSTALL HIGH AND LOW CLUTCH SLEEVE INSTALL NEEDLE ROLLER BEARING AND IDLER LOW GEAR Apply gear oil to the needle roller bearing. Install the needle roller bearing and idler low gear. INSTALL REAR TAPER ROLLER BEARING Using SST and a press, install the rear taper roller bear- ing.
  • Page 177 TR-19 TRANSFER - COMPONENT PARTS (CENTER DIFFERENTIAL ASSEMBLY) Center Differential Assembly COMPONENTS DISASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY CHECK OIL CLEARANCE AND THRUST CLEARANCE OF HIGH SPEED GEAR Using a feeler gauge, measure the high speed gear thrust clearance. Standard clearance: 0.10 —...
  • Page 178 TR-20 TRANSFER - COMPONENT PARTS (CENTER DIFFERENTIAL ASSEMBLY) REMOVE FRONT DRIVE GEAR PIECE Using snap ring pliers, remove the snap ring. Using SST and a press, remove the front drive gear piece. SST 09950-20017, 09950-00020 NOTICE: Be careful do not drop the center differential assembly.
  • Page 179 TR-21 TRANSFER - COMPONENT PARTS (CENTER DIFFERENTIAL ASSEMBLY) REMOVE HIGH AND LOW CLUTCH SLEEVE ASSEMBLY REMOVE HIGH AND LOW CLUTCH SLEEVE SHIFTING KEYS AND SPRINGS Using a screwdriver, remove the two shifting key springs and shifting keys. REMOVE HIGH SPEED OUTPUT GEAR BUSHING, CLUTCH HUB AND SHIFTING KEY RETAINER (a) Using SST and a press, remove the high speed output gear bushing, clutch hub and shifting key retainer.
  • Page 180 TR-22 TRANSFER - COMPONENT PARTS (CENTER DIFFERENTIAL ASSEMBLY) 1 1 . REMOVE DIFFERENTIAL REAR CASE Remove the twelve bolts and differential rear case. 12. REMOVE REAR SIDE GEAR AND THRUST WASHER 13. REMOVE PINION SHAFT, PINION GEAR AND THRUST WASHER Remove the straight pin.
  • Page 181 TR-23 TRANSFER - COMPONENT PARTS (CENTER DIFFERENTIAL ASSEMBLY) ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY INSTALL PINION SHAFT, PINION GEAR AND THRUST WASHER HINT: Coat all of the sliding and rotating surface with gear oil before assembly. Install the front side gear and thrust washer to the differ- ential front case.
  • Page 182 TR-24 TRANSFER - COMPONENT PARTS (CENTER DIFFERENTIAL ASSEMBLY) INSTALL REAR SIDE GEAR AND THRUST WASHER INSTALL DIFFERENTIAL REAR CASE Temporary install the differential rear case and set bolts. 5. TORQUE REAR CASE SET BOLTS Torque the rear case set bolts. Torque: 88 N-m (900 kgf-cm, 65 ftlbf) Loosen the rear case set bolts.
  • Page 183 TR-25 TRANSFER - COMPONENT PARTS (CENTER DIFFERENTIAL ASSEMBLY) INSTALL REAR TAPER ROLLER BEARING Using a press, install the rear taper roller bearing. INSTALL SHIFTING KEY RETAINER Using a plastic hammer, tap in the shifting key retainer. INSERT CLUTCH HUB INTO HIGH AND LOW CLUTCH SLEEVE Install the clutch hub and shifting keys to the high and low clutch sleeve.
  • Page 184 TR-26 TRANSFER - COMPONENT PARTS (CENTER DIFFERENTIAL ASSEMBLY) 1 1 . INSTALL HIGH SPEED OUTPUT GEAR AND NEEDLE ROLLER BEARING Apply gear oil to the needle roller bearing. Place the synchronizer ring on the gear and install the high speed output gear and needle roller bearing. NOTICE: Align the ring slots with the shifting keys.
  • Page 185 TR-27 TRANSFER - COMPONENT PARTS (CENTER DIFFERENTIAL ASSEMBLY) 15. MEASURE OIL CLEARANCE AND THRUST CLEARANCE OF HIGH SPEED OUTPUT GEAR Using a feeler gauge, measure the high speed gear thrust clearance. Standard clearance: 0.10 — 0.25 mm (0.0039 - 0.0098 in.) Maximum clearance: 0.25 mm (0.0098 in.) Using a dial indicator, measure the high speed gear oil...
  • Page 186 TR-28 TRANSFER - COMPONENT PARTS (FRONT EXTENSION HOUSING ASSEMBLY) Front Extension Housing Assembly COMPONENTS DISASSEMBLY OF FRONT EXTENSION HOUSING ASSEMBLY REMOVE DRIVE CLUTCH HUB (a) Using snap ring pliers, remove the snap ring. (b) Using SST, remove the drive clutch hub. SST 09950-2001 7...
  • Page 187 TR-29 TRANSFER - COMPONENT PARTS (FRONT EXTENSION HOUSING ASSEMBLY) REMOVE FRONT OUTPUT SHAFT Using a plastic hammer, drive out the front output shaft. REMOVE DUST DEFLECTORS (a) Using SST and a press, remove the dust deflector. SST 09950-00020 (b) Using a screwdriver and hammer, tap the dust deflector and remove it.
  • Page 188 TR-30 TRANSFER - COMPONENT PARTS (FRONT EXTENSION HOUSING ASSEMBLY) (b) Using SST and a press, remove the ball bearing. SST 09316-60010 (09316-00010, 09316-00070) ASSEMBLY OF FRONT EXTENSION HOUSING ASSEMBLY INSTALL DUST DEFLECTORS Using SST and a press, install the dust deflector. SST 09223-41020, 09223-1 5020 (b) Using SST and a press, install the dust deflector.
  • Page 189 TR-31 TRANSFER - COMPONENT PARTS (FRONT EXTENSION HOUSING ASSEMBLY) INSTALL OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09316-60010 (09316-00010, 09316-00060) INSTALL FRONT OUTPUT SHAFT AND DRIVE CLUTCH Using SST and press, install the front output shaft and drive clutch hub.
  • Page 190 TR-32 TRANSFER - COMPONENT PARTS (REAR EXTENSION HOUSING ASSEMBLY) Rear Extension Housing Assembly COMPONENTS...
  • Page 191 TR-33 TRANSFER - COMPONENT PARTS (REAR EXTENSION HOUSING ASSEMBLY) DISASSEMBLY OF REAR EXTENSION HOUSING ASSEMBLY REMOVE OIL PUMP DRIVE SHAFT REMOVE OIL PUMP COVER (a) Using a torx socket wrench, remove the three screws. (Torx socket wrench T30 09042-00010) Install two suitable bolts to the pump cover. (c) Remove the pump cover from rear extension housing.
  • Page 192 TR-34 TRANSFER - COMPONENT PARTS (REAR EXTENSION HOUSING ASSEMBLY) REMOVE SCREW PLUG, SPRING, BALL AND VALVE SEAT Using a hexagon wrench, remove the screw plug. Using a magnetic finger, remove the spring, ball and valve seat. REMOVE CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY Using snap ring pliers, remove the snap ring.
  • Page 193 TR-35 TRANSFER - COMPONENT PARTS (REAR EXTENSION HOUSING ASSEMBLY) REMOVE SPEED METER DRIVE GEAR Using snap ring pliers, remove the snap ring. Remove the speedometer drive gear. 10. REMOVE REAR OUTPUT SHAFT Using snap ring pliers, remove the snap ring. Using SST and a hammer, remove the rear output shaft.
  • Page 194 TR-36 TRANSFER - COMPONENT PARTS (REAR EXTENSION HOUSING ASSEMBLY) (b) Using a screwdriver and hammer, remove the rear output shaft dust deflector. 12. REMOVE OIL SEAL Using a screwdriver, pry out the oil seal. 13. REMOVE BALL BEARING (a) Using a screwdriver, remove the snap ring. (b) Using SST and a press, remove the ball bearing.
  • Page 195 TR-37 TRANSFER - COMPONENT PARTS (REAR EXTENSION HOUSING ASSEMBLY) If the body clearance is greater than the maximum, re- place the drive rotor or driven rotor. CHECK TIP CLEARANCE OF DRIVEN ROTOR Using a feeler gauge, measure tip clearance between drive rotor and driven rotor.
  • Page 196 TR-38 TRANSFER - COMPONENT PARTS (REAR EXTENSION HOUSING ASSEMBLY) INSTALL DUST DEFLECTORS Using SST and a hammer, install a new rear extension housing dust deflector. SST 09316-60010 (09316-00010, 09316-00040) Using SST and a press, install a new rear extension hous- ing dust deflector.
  • Page 197 TR-39 TRANSFER - COMPONENT PARTS (REAR EXTENSION HOUSING ASSEMBLY) INSTALL SPEEDOMETER DRIVE GEAR Install the speedometer drive gear. Using snap ring pliers, install the snap ring. INSTALL OIL PUMP PLATE SEPARATOR Install the oil pump plate. Install the separator. Install and torque the three bolts. Torque: 4.9 Nm (50 kgfcm, 43 in.lbf) INSTALL CENTER DIFFERENTIAL CONTROL COUPLING...
  • Page 198 TR-40 TRANSFER - COMPONENT PARTS (REAR EXTENSION HOUSING ASSEMBLY) Apply liquid sealer to the screw plug. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent (d) Using a hexagon wrench, install and torque the screw plug. Torque: 29 N-m (300 kgfcm, 21 ft-lbf) INSTALL DRIVEN ROTOR (a) Apply gear oil to the driven rotor.

  • Page 199: Transfer Assembly

    TR-41 TRANSFER - TRANSFER ASSEMBLY TRANSFER ASSEMBLY INSTALL TWO BEARING RACES TO FRONT CASE Using SST and a hammer, install the center differential bearing race. SST 09316-60010 (09316-00010, 09316-00030) 09316-20011 Using SST and a hammer, install the idle gear bearing race.
  • Page 200 TR-42 TRANSFER - TRANSFER ASSEMBLY Install the washer and nut. Torque: 12 Nm (120 kgf-cm, 9 ft-lbf) ASSEMBLE SHIFT FORK NO.1 AND FORK SHAFT Using a pin punch and a hammer, drive in the slotted spring pin. INSTALL IDLE GEAR ASSEMBLY, CENTER DIFFEREN- TIAL ASSEMBLY AND HIGH AND LOW SHIFT FORK AS- SEMBLY TO FRONT CASE INSTALL INPUT SHAFT ASSEMBLY...
  • Page 201 TR-43 TRANSFER - TRANSFER ASSEMBLY INSTALL OIL STRAINER TO REAR CASE Install the oil strainer. Install and torque the bolts. Torque: 4.9 Nm (50 kgfcm, 43 in.-lbf) ASSEMBLE FRONT CASE AND REAR CASE Remove any packing material and be careful not to drop oil on the contacting surfaces of the front case.
  • Page 202 TR-44 TRANSFER - TRANSFER ASSEMBLY 10. INSTALL CASE COVER Remove any packing material and be careful not to drop oil on the contacting surfaces of the rear case. Apply seal packing to the rear case as shown. Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent HINT: Install the case cover as soon as the seal packing...
  • Page 203 TR-45 TRANSFER - TRANSFER ASSEMBLY 12. INSTALL ADJUSTING SHIMS TO IDLER GEAR AND OUTPUT SHAFT TAPER ROLLER BEARINGS Apply MP grease to the adjusting shims. Install the adjusting shims to bearing outer races. HINT: Install the thinner shim on the bearing outer race side.
  • Page 204 TR-46 TRANSFER - TRANSFER ASSEMBLY 15. ASSEMBLE SHIFT FORK NO.2 AND FORK SHAFT Assemble the shift fork No.2 and fork shaft. Using a brass bar and hammer, tap in the snap rings. 16. INSTALL CLUTCH SLEEVE, SHIFT FORK NO.2 AND FORK SHAFT 17.
  • Page 205 TR-47 TRANSFER - TRANSFER ASSEMBLY 18. (w / POWER TAKE-OFF) INSTALL POWER TAKE-OFF CASE Install the power take-off case and a new gasket. Apply liquid sealer to the bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344. LOCTITE 242 or equivalent Install and torque the ten bolts.
  • Page 206 TR-48 TRANSFER - TRANSFER ASSEMBLY 22. INSTALL OUTPUT GEAR Apply gear oil to the output gear. Install the output gear. NOTICE: Do not turn the output gear. 23. INSTALL MOTOR ACTUATOR Remove any packing material and be careful not to drop oil on the contacting surfaces of the front case.

  • Page 207: System Inspection

    TR-49 TRANSFER - MOTOR SHIFT CONTROL SYSTEM MOTOR SHIFT CONTROL SYSTEM PARTS LOCATION SYSTEM INSPECTION INSPECT SHIFT LEVER POSITION Start the engine, and center differential lock switch turned to OFF. Check that the center differential indicator light comes on when the transfer shift lever shifted to L position. Check that the light goes off when the lever is shifted to N or H position.
  • Page 208 TR-50 TRANSFER - MOTOR SHIFT CONTROL SYSTEM PARTS INSPECTION INSPECT CENTER DIFFERENTIAL LOCK CONTROL RE- Check that there is continuity between terminals as shown in the chart. HINT: There is a diode between terminals 6 and 7. If the circuit shown no continuity, change the positive ( + ) and negative ( —) probes and recheck the circuit.
  • Page 209 TR-51 TRANSFER - SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA...
  • Page 210 TR-52 TRANSFER - SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS...
  • Page 211 PR-1 PROPELLER SHAFT REFER TO LAND CRUISER (STATION WAGON) REPAIR MANUAL FOR CHASSIS AND BODY (Pub. No. RM184E) NOTE: The following pages contain only the points which differ from the above listed man- ual. (STATION WAGON) DESCRIPTION PR-2 PROPELLER SHAFT...
  • Page 212 PR-2 PROPELLER SHAFT (STATION WAGON) - DESCRIPTION DESCRIPTION DESCRIPTION The propeller shaft is connected to the front differential and the transfer via two joints.
  • Page 213 PR-3 PROPELLER SHAFT (STATION WAGON) - PROPELLER SHAFT PROPELLER SHAFT COMPONENTS...
  • Page 214 PR-4 PROPELLER SHAFT (STATION WAGON) - PROPELLER SHAFT PROPELLER SHAFT ASSEMBLY HINT: When replacing the spider, be sure that the grease fitting assembly hole is facing in the direction shown in the illustration.
  • Page 215 SA-1 SUSPENSION AND AXLE REFER TO FOLLOWING REPAIR MANUALS: NOTE: The following pages contain only the points which differ from the above listed manuals. (HARDTOP & CANVAS TOP) FRONT DIFFERENTIAL SA-2 ASSEMBLY REMOVAL AND INSTALLATION SA-2 (STATION WAGON) WHEEL ALIGNMENT SA-3 PRIMARY INSPECTION SA-3...
  • Page 216 SA 2 SUSPENSION AND AXLE (HARDTOP & CANVAS TOP) - FRONT DIFFERENTIAL FRONT DIFFERENTIAL ASSEMBLY REMOVAL AND INSTALLATION COMPONENTS...

  • Page 217: Wheel Alignment

    SA-3 SUSPENSION AND AXLE (STATION WAGON) - WHEEL ALIGNMENT WHEEL ALIGNMENT PRIMARY INSPECTION MAKE FOLLOW CHECKS AND CORRECT ANY PRO- BLEMS Check the tires for wear and proper inflation. Cold tire inflation pressure: See page SA-7 Check the tire runout. Tire runout: 3.0 mm (0.118 in.) or less Check the wheel bearings for looseness.

  • Page 218: Front Wheel Alignment

    SA-4 SUSPENSION AND AXLE (STATION WAGON) - WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT INSTALL WHEEL ALIGNMENT EQUIPMENT Follow the specific instructions of the equipment manufacturer. INSPECT CAMBER AND STEERING AXIS INCLINATION Camber: 1°00' ± 45' (1.00° ± 0.75°) Cross camber: 30' or less (0.50° or less) Steering axis inclination: 13°00' ±...
  • Page 219 SA-5 SUSPENSION AND AXLE (STATION WAGON) - WHEEL ALIGNMENT HINT: The clamps opening must be positioned at the rear of the tie rod and and face within 60° ± 10° from the verticle axis. INSPECT WHEEL ANGLE Remove the caps of the knuckle stopper bolts and check the steering angles.
  • Page 220 SA-6 SUSPENSION AND AXLE (STATION WAGON) - FRONT DIFFERENTIAL FRONT DIFFERENTIAL ASSEMBLY REMOVAL AND INSTALLATION COMPONENTS...

  • Page 221: Station Wagon

    SA-7 SUSPENSION AND AXLE - SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA (STATION WAGON)
  • Page 222 SA-8 SUSPENSION AND AXLE - SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS (HARDTOP & CANVAS TOP) (STATION WAGON)

  • Page 223: Brake System

    BR-1 BRAKE SYSTEM REFER TO LAND CRUISER (STATION WAGON) REPAIR MANUAL FOR CHASSIS AND BODY (Pub. No. RM184E) NOTE: The following pages contain only the points which differ from the above listed manual. (STATION WAGON) PREPARATION BR-2 CHECK AND ADJUSTMENT...

  • Page 224: Recommended Tools

    09990-00163 ABS Actuator Checker Sheet " A " w/ ABS 09990-00200 ABS Actuator Checker Sub-harness " C " w/ ABS 09990-00210 ABS Actuator Checker Sub-harness " E " w/ABS RECOMMENDED TOOLS 09082-00015 TOYOTA Electrical Tester 09905-00013 Snap Ring Pillers EQUIPMENT Torque w r e n c h...
  • Page 225 BR-3 BRAKE SYSTEM (STATION WAGON) - PREPARATION LUBRICANT Item Capacity Classification Brake fluid SAE J17O3 or FMVSS No.116 DOT 3...
  • Page 226 BR-4 BRAKE SYSTEM (STATION WAGON) - CHECK AND ADJUSTMENT CHECK AND ADJUSTMENT BRAKE PEDAL CHECK AND ADJUSTMENT CHECK THAT PEDAL HEIGHT IS CORRECT, AS SHOWN Pedal height from asphalt sheet: 167.5 - 177.5 mm (6.59 - 6.99 in.) If the pedal height is incorrect, adjust it. IF NECESSARY, ADJUST PEDAL HEIGHT Disconnect the connector from the stop light switch.
  • Page 227 BR-5 BRAKE SYSTEM (STATION WAGON) - CHECK AND ADJUSTMENT CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT, AS SHOWN Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 Ibf): More than 68 mm (2.68 in.) If the reserve distance is incorrect, troubleshoot the...

  • Page 228: Master Cylinder

    BR-6 BRAKE SYSTEM (STATION WAGON) - MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER REMOVAL Brake Booster w/o ABS Master Cylinder Clamp Gasket Bracket w/ ABS Brake Booster Master Cylinder Gasket Clamp (RHD) (LHD) Bracket 3-Way Specified torque Non-reusable part...
  • Page 229 BR-7 BRAKE SYSTEM (STATION WAGON) - MASTER CYLINDER DISCONNECT LEVEL WARNING SWITCH CONNECTOR TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted sur- face. Wash it off immediately. DISCONNECT BRAKE LINES Using SST, disconnect brake lines from the master cylinder.
  • Page 230 BR-8 BRAKE SYSTEM (STATION WAGON) - MASTER CYLINDER COMPONENTS w/o ABS Strainer Reservoir Boot No. 1 Piston and Spring Grommet Snap Ring No. 2 Piston and Spring Gasket Clamp Piston Stopper Bolt w/ ABS Strainer Reservoir No. 1 Piston and Spring Grommet Snap Ring No.
  • Page 231 BR-9 BRAKE SYSTEM (STATION WAGON) - MASTER CYLINDER MASTER CYLINDER DISASSEMBLY REMOVE MASTER CYLINDER BOOT Using a screwdriver, remove the master cylinder boot. REMOVE RESERVOIR CAP AND STRAINER Turn the reservoir cap to the " O P E N " side and remove it. Remove the strainer.

  • Page 232: Master Cylinder Assembly

    BR-10 BRAKE SYSTEM (STATION WAGON) - MASTER CYLINDER Place a rag and t w o wooden blocks on the work table and lightly tap the cylinder flange against the blocks until the piston drops out of the cylinder. HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 in.).
  • Page 233 BR-11 BRAKE SYSTEM (STATION WAGON) - MASTER CYLINDER INSTALL NO.2 PISTON STOPPER BOLT Using a screwdriver, push the piston in all the way and in- stall the No.2 piston stopper bolt over a new gasket. Torque: 10 Nm (100 kgfcm, 7 ftlbf) INSTALL TWO GROMMETS INSTALL RESERVOIR Install the strainer to the reservoir.
  • Page 234 BR-12 BRAKE SYSTEM (STATION WAGON) - MASTER CYLINDER INSTALL MASTER CYLINDER (w/ ABS) Install the master cylinder, gasket, 3-way, clamp and bracket on the brake booster with the four nuts. (w/o ABS) Install the master cylinder, gasket, clamp and bracket on the brake booster with the four nuts.
  • Page 235 BRAKE SYSTEM (STATION WAGON) - LOAD SENSING PROPORTIONING BR-13 AND BY-PASS VALVE (LSP & BV) LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) COMPONENTS Set Plate Valve Bracket Load Sensing Proportioning and By-pass Valve Load Sensing Spring Assembly Plate Washer Plate Washer Load Sensing Valve Boot Shackle No.1...
  • Page 236 BRAKE SYSTEM (STATION WAGON) - LOAD SENSING PROPORTIONING BR-14 AND BY-PASS VALVE (LSP & BV) FLUID PRESSURE CHECK AND ADJUSTMENT SET REAR AXLE LOAD Rear axle load (include vehicle weight): 1,330 kg (2,932 Ib) INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 09709-29017 RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm...
  • Page 237 BRAKE SYSTEM (STATION WAGON) - LOAD SENSING PROPORTIONING BR-15 AND BY-PASS VALVE (LSP & BV) In event the pressure cannot be adjusted by No.2 shackle, raise or lower the valve body. Low pressure — Lower High pressure — Raise (d) Torque the nuts. Torque: 13 N-m (130 kgf-cm, 9 ftlbf) (e) Adjust the length of the No.2 shackle again.
  • Page 238 BRAKE SYSTEM (STATION WAGON) - LOAD SENSING PROPORTIONING BR-16 AND BY-PASS VALVE (LSP & BV) Remove the valve bracket and mounting bolts, then remove the LSP & BV assembly. LSP & BV ASSEMBLY DISASSEMBLY REMOVE VALVE BRACKET Remove the nut and bolt as shown. Remove the two nuts, and remove the bracket and two bolts from the valve body.
  • Page 239 BRAKE SYSTEM (STATION WAGON) - LOAD SENSING PROPORTIONING BR-17 AND BY-PASS VALVE (LSP & BV) LSP & BV INSPECTION INSPECT VALVE PISTON PIN AND LOAD SENSING SPR- ING CONTACT SURFACE FOR WEAR Wear limit: 0.7 mm (0.028 in.) LSP & BV ASSEMBLY ASSEMBLE FOLLOWING PARTS TO LOAD SENSING SPRING: Load sensing valve boot...
  • Page 240 BRAKE SYSTEM (STATION WAGON) - LOAD SENSING PROPORTIONING BR-18 AND BY-PASS VALVE (LSP & BV) INSTALL VALVE BRACKET Install the two set bolts to the valve assembly through the valve bracket and temporarily tighten the two valve body mounting nuts. Torque the bolt and nut through the two plate washers.
  • Page 241 BRAKE SYSTEM (STATION WAGON) - LOAD SENSING PROPORTIONING BR-19 AND BY-PASS VALVE (LSP & BV) CONNECT BRAKE LINES Using SST, connect the brake lines. SST 09751-36011 Torque: 15 Nm (155 kgfcm, 11 ft-lbf) SET REAR AXLE LOAD (See page BR-16) SET VALVE BODY When pulling down the load sensing spring, confirm that the valve piston moves down smoothly.
  • Page 242 BR-20 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) ANTI-LOCK BRAKE SYSTEM (ABS) DESCRIPTION • The ABS is a brake system which controls the brake cylinder hydraulic pressure of all four wheels during sudden braking and braking on slippery road surfaces, preventing the wheels from locking. This ABS pro- vides the following benefits: (1) Enables steering round an obstacle with a greater degree of certainty even when panic braking.
  • Page 243 BR-21 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) COMPONENTS FUNCTION Component Function Front Speed Sensor Detect the wheel speed of each of the left and right front wheels. Rear Speed Sensor Detect the wheel speed of each of the left and right rear wheels. Lights up to alert the driver when trouble has occurred in the Anti- ABS Warning Light Lock Brake System and when the center differential is locked.

  • Page 244: Wiring Diagram

    BR-22 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
  • Page 245 BR-23 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) CONNECTORS ABS Actuator CONNECTOR A CONNECTOR B Control Relay Deceleration Sensor Front Speed Sensor Rear Speed Sensor (LH) Rear Speed Sensor (RH) ABS ECU...
  • Page 246 BR-24 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM DESCRIPTION If a malfunction occurs, the system will identify the pro- blem and the ECU will store the codes for the trouble items. At the same time, the system informs the driver of a malfunction via the "...
  • Page 247 BR-25 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) READ DIAGNOSTIC CODE Turn the ignition switch on. Using SST, connect terminals of the check con- nector. SST 09843-18020 Pull out the short pin from the terminals WA and WB of the check connector in the engine room.
  • Page 248 BR-26 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CODE...
  • Page 249 BR-27 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CODES CLEARING CLEAR DIAGNOSTIC CODES Confirm that the center differential is free. Turn the ignition switch on. Using SST, connect terminals Tc and of the check con- nector. SST 09843-18020 HINT: Keep the vehicle stopped vehicle speed 0 km/h (0 mph).
  • Page 250 BR-28 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING Problem Always comes on after ignition switch is turned on. Does not come on for 3 seconds after ignition switch on. Goes on and off. Comes on while running. Does not light up when the transfer is in L (center differential lock) position.
  • Page 251 BR-29 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) Continued from page BR-28 Is connector of ECU properly connected? Faulty ECU connector. And are all terminals in the connector? Is there 10 - 16 V between terminal IG on ECU wire harness side connector and Faulty power circuit.
  • Page 252 BR-30 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) "ABS" warning light does not come on for 3 seconds after ignition switch on. Pull out the short pin and ground the terminal W of the female side connector. (Ignition switch on) Bulb burned out or open circuit in wire Does warning light come on? harness between warning light and control...
  • Page 253 BR-31 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) "ABS" warning light comes on and off. Check for short circuit in wire harness between terminal of check connector. Brakes pull. Braking inefficient. ABS operates at ordinary braking. ABS operates just before stopping at ordinary braking. Brake pedal pulsates abnormally while ABS is operating.
  • Page 254 BR-32 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) Continued from page BR-31 Is there foreign material or ferric chips on the sensor tip? Clean chips from the speed sensor. Try deceleration sensor operation diagnosis system. Faulty deceleration sensor or sensor in- (See page BR-38) is sensor operation OK? stallation faulty.
  • Page 255 BR-33 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) Does not light up when the transfer is in L position. When the transfer is in L position, the ABS operates. When the transfer is in L position, does the center dif- Open circuit in center differential lock in- ferential lock indicator light come on? dicator switch or wire harness.
  • Page 256 BR-34 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) SPEED SENSOR AND DECELERATION SENSOR DIAGNOSIS SYSTEM DIAGNOSIS SYSTEM INSPECTION PRECAUTION While checking the speed sensor diagnosis system, ABS does not operate and brake system operates as normal brake system. 1.
  • Page 257 BR-35 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) INSPECT SPEED SENSOR SIGNAL CHANGE Drive the faster than 45 km/h (28 mph) for several seconds. Check the warning light signal. If the warning light signal is abnormal, perform the steps 6 and 7.
  • Page 258 BR-36 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) REPAIR MALFUNCTIONING PARTS Repair or replace the malfunctioning parts. HINT: When repairing or replacing parts, turn the igni- tion switch to OFF. REMOVE SST Remove the SST from terminals of the check connector.
  • Page 259 BR-37 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CODE...
  • Page 260 BR-38 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) DECELERATION SENSOR OPERATION DIAGNOSIS SYSTEM PRECAUTION While checking the deceleration sensor operating diagnosis system, the Anti-lock Brake System does not work and brake system works as normal brake system. DIAGNOSIS SYSTEM INSPECTION 1.
  • Page 261 BR-39 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) Jack up the front side of the vehicle slowly as shown. HINT: When measuring the height, measure at the center of the lower body of the vehicle. Check that the warning light does not turn on. If the warning light turns on, inspect the deceleration sen- sor installation.
  • Page 262 BR-40 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown. Control Relay ABS Actuator Clamp Rubber Cushion Holder Actuator Bracket Specified torque...
  • Page 263 BR-41 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION DISCONNECT AND CONNECT BRAKE LINES Using SST, disconnect and connect the brake lines from/to the ABS actuator. SST 09023-00100 Torque: 15 Nm (155 kgfcm, 11 ftlbf) BLEED BRAKE SYSTEM (See pub No.RM184E, page BR-7)
  • Page 264 BR-42 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR INSPECTION 1. INSPECT BATTERY VOLTAGE Battery voltage: 10 - 14.5 V DISCONNECT CONNECTORS Disconnect the connector from the actuator. Remove the control relay from the actuator bracket. Disconnect the two connectors from the control relay. CONNECT ACTUATOR CHECKER (SST) TO ACTUATOR Connect the actuator checker (SST) to the actuator, con- trol relay and body side wire harness through the sub-...
  • Page 265 BR-43 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) INSPECT BRAKE ACTUATOR OPERATION Start the engine, and run it at idle. Turn the selector switch of the actuator checker to "FRONT RH" position. Push and hold in the MOTOR SWITCH for a few seconds. Depress the brake pedal and hold it until the step (g) is completed.
  • Page 266 BR-44 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) PUSH SUB MOTOR SWITCH Push and hold in the SUB MOTOR switch for a few seconds. Stop the engine. DISCONNECT ACTUATOR CHECKER (SST) FROM AC- TUATOR Disconnect the actuator checker (SST) and sub-wire harness (SST) from the actuator, control relay and body side wire harness.
  • Page 267 BR-45 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) CONTROL RELAY CONTROL RELAY INSPECTION INSPECT CONTINUITY OF MOTOR RELAY CIRCUIT Check that there is continuity between terminals 9 and Check that there is no continuity between terminals 7 and 8. If continuity is not as specified, replace the relay.

  • Page 268: Front Speed Sensor

    BR-46 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) FRONT SPEED SENSOR COMPONENTS Front Speed Sensor Sensor Rotor Specified torque FRONT SPEED SENSOR INSPECTION INSPECT SPEED SENSOR Disconnect the speed sensor connector. Measure the resistance between terminals FR + , FR — and FL + , F L - .
  • Page 269 BR-47 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) Check that there is no continuity between each terminal and sensor body. If there is continuity, replace the sensor. Connect the speed sensor connector. INSPECT SENSOR INSTALLATION Check that the sensor installation bolt is tightened proper- ly.
  • Page 270 BR-48 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) FRONT SPEED SENSOR REMOVAL HINT: When replacing the sensor or sensor harness, replace the sensor and sensor harness together as a set. Disconnect the speed sensor connector. DISCONNECT SPEED SENSOR CONNECTOR REMOVE SPEED SENSOR Remove the four clamp bolts holding the sensor harness RH from the axle housing.
  • Page 271 BR-49 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) Install the sensor harness RH with the clamps and bolts in place. Torque: 18 N-m (185 kgf-cm, 13 ft-lbf) Connect the speed sensor connector. Torque: 18 N-m (185 kgfcm, 13 ft-lbf) INSTALL SPEED SENSOR HINT: When replacing the sensor, adjust the air gap.
  • Page 272 BR-50 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) (d) If diagnosis code 71 or 72 is displayed, replace the 0.5 mm spacer inserted in the speed sensor with a 0.35 mm spacer. (1) Using a screwdriver to remove the 0.5 mm spacer. (2) Using needle-nose pliers to install the 0.35 mm spacer.

  • Page 273: Rear Speed Sensor

    BR-51 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR COMPONENTS Rear Speed Sensor Disc Brake Assembly Brake Disc Specified torque REAR SPEED SENSOR INSPECTION INSPECT SPEED SENSOR Disconnect the speed sensor connector. Measure the resistance between terminals. Resistance: 0.7 - 1.1 kQ If resistance value is not as specified, replace the sensor.
  • Page 274 BR-52 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) Check that there is no continuity between each terminal and sensor body. If there is continuity, replace the sensor. Connect the speed sensor connector. INSPECT SENSOR INSTALLATION Check that the sensor installation bolt is tightened proper- ly.
  • Page 275 BR-53 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR REMOVAL HINT: When replacing the sensor or sensor harness, replace the sensor and sensor harness together as a set. DISCONNECT SPEED SENSOR CONNECTOR Disconnect the speed sensor connector. Remove the five clamp bolts holding the sensor wire harness from the suspension arm and frame.
  • Page 276 BR-54 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) Install the sensor harness with the clamps and bolts in place. INSPECT SPEED SENSOR AND DECELERATION SENSOR DIAGNOSIS SYSTEM...
  • Page 277 BR-55 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) ANTI-LOCK BRAKE SYSTEM CIRCUIT SYSTEM CIRCUIT INSPECTION INSPECT SYSTEM CIRCUIT WITH CONNECTOR CON- NECTED Remove the ABS ECU. Using a voltmeter with high impedance (10 kfl/V minimum), measure the voltage at each terminal and body ground.
  • Page 278 BR-56 BRAKE SYSTEM (STATION WAGON) - ANTI-LOCK BRAKE SYSTEM (ABS) If the circuit is not as specified, check and repair or replace the trouble part shown in the table above. INSPECT SYSTEM CIRCUIT WITH CONNECTOR DISCON- NECTED Disconnect the connectors from the ECU, inspect at the wire harness side connector.
  • Page 279 BR-57 BRAKE SYSTEM (STATION WAGON) - SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA TORQUE SPECIFICATIONS...

  • Page 280: Body Electrical System

    BE-1 BODY ELECTRICAL SYSTEM REFER TO FOLLOWING REPAIR MANUALS: NOTE: The following pages contain only the points which differ from the above listed manuals. (HARDTOP, CANVAS TOP & STATION WAGON) WIPER AND WASHER SYSTEM BE-2 COMBINATION METER BE-3 POWER SEAT CONTROL SYSTEM BE-21 CRUISE CONTROL SYSTEM BE-29...
  • Page 281 BE-2 BODY ELECTRICAL SYSTEM - WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM FRONT WIPER MOTOR FRONT WIPER MOTOR INSPECTION OPERATION AT LOW SPEED Connect the positive ( + ) lead from the battery to ter- minal 3 and negative ( —) lead to terminal 1, check that the motor operates at low speed.

  • Page 282: Combination Meter

    BE-3 BODY ELECTRICAL SYSTEM - COMBINATION METER COMBINATION METER PARTS LOCATION...
  • Page 283 BE-4 BODY ELECTRICAL SYSTEM - COMBINATION METER METER CIRCUIT...
  • Page 284 BE-5 BODY ELECTRICAL SYSTEM - COMBINATION METER METER CIRCUIT...
  • Page 285 BE 6 BODY ELECTRICAL SYSTEM - COMBINATION METER METER CIRCUIT...
  • Page 286 BE-7 BODY ELECTRICAL SYSTEM - COMBINATION METER...
  • Page 287 BE-8 BODY ELECTRICAL SYSTEM - COMBINATION METER TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
  • Page 288 BE-9 BODY ELECTRICAL SYSTEM - COMBINATION METER...
  • Page 289 BE-10 BODY ELECTRICAL SYSTEM - COMBINATION METER SPEEDOMETER SYSTEM INSPECT SPEEDOMETER (ON-VEHICLE) Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will in- crease the indication error.
  • Page 290 BE-11 BODY ELECTRICAL SYSTEM - COMBINATION METER TACHOMETER SYSTEM TACHOMETER INSPECTION INSPECT TACHOMETER (ON-VEHICLE) Connect a tune-up test tachometer, and start the engine. NOTICE: • Reversing the connection of the tachometer will damage the transistors and diodes inside. • When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks.
  • Page 291 BE-12 BODY ELECTRICAL SYSTEM - COMBINATION METER FUEL SENDER GAUGE INSPECTION OPERATION Connect a series of three 1.5 volts dry cell batteries. Connect the positive ( + ) lead from the dry cell batteries to terminal 4 through a 3.4 watts test bulb and the negative ( —) lead to terminal 5.
  • Page 292 BE-13 BODY ELECTRICAL SYSTEM - COMBINATION METER WATER TEMPERATURE GAUGE SYSTEM WATER TEMPERATURE RECEIVER GAUGE INSPECTION OPERATION Disconnect the connector from the sender gauge. (b) Turn the ignition switch ON, check that the receiver gauge needle indicates COOL. Ground terminal on the wire harness side connector through a 3.4 watts test bulb.
  • Page 293 BE-14 BODY ELECTRICAL SYSTEM - COMBINATION METER VOLTMETER SYSTEM INSPECT VOLTMETER (ON-VEHICLE) Compare the tester and voltmeter indications. If error is excessive, replace the voltmeter. RESISTANCE Measure the receiver gauge resistance between ter- minals. Resistance: 90 - 110 Q If resistance value is not as specified, replace the receiver gauge.
  • Page 294 BE-15 BODY ELECTRICAL SYSTEM - COMBINATION METER OIL PRESSURE GAUGE SYSTEM OIL PRESSURE RECEIVER GAUGE INSPECTION OPERATION Disconnect the connector from the sender gauge. (b) Turn the ignition switch ON, check that the receiver gauge needle indicates LOW. (c) Ground terminal on the wire harness side through a 3.4 W test bulb.

  • Page 295: Brake Warning System

    BE-16 BODY ELECTRICAL SYSTEM - COMBINATION METER BRAKE WARNING SYSTEM BRAKE WARNING LIGHT INSPECTION INSPECT WARNING LIGHT Disconnect the connectors from the level warning switch, parking brake switch. Connect terminals on the wire harness side connector of the level warning switch connector. Turn the ignition switch ON, check that the warning light lights up.

  • Page 296: Seat Belt Warning System

    BE-17 BODY ELECTRICAL SYSTEM - COMBINATION METER SEAT BELT WARNING SYSTEM SEAT BELT WARNING INSPECTION INSPECT WARNING LIGHT Disconnect the connector from the seat belt warning relay. (b) Ground terminal 2 on the wire harness side connector. (c) Turn the ignition switch ON, check that the warning light lights up.
  • Page 297 BE-18 BODY ELECTRICAL SYSTEM - COMBINATION METER If circuit is as specified, try another relay. TIRE HALF-LOCK WARNING SYSTEM TIRE HALF-LOCK WARNING INSPECTION INSPECT WARNING LIGHT Disconnect the connector from the door courtesy switch and ground terminal on the wire harness side connector. (b) Turn the ignition switch ON, check that the warning light lights up.
  • Page 298 BE-19 BODY ELECTRICAL SYSTEM - COMBINATION METER ENGINE OIL LEVEL WARNING SYSTEM INSPECT WARNING LIGHT Disconnect the connector from the engine oil level sen- sor. Ground terminal 2 on the wire harness side connector. Turn the ignition switch ON, check that the warning light lights up.
  • Page 299 BE-20 BODY ELECTRICAL SYSTEM - COMBINATION METER HINT: Illumination lights with adjustable brightness. • Cigarette Lighter • Ash Receptacle • Antenna Switch • Defogger Switch • Headlight Cleaner Switch • Audio • A/C Control Assembly • Center Diff. Lock Switch •...
  • Page 300 BE-21 BODY ELECTRICAL SYSTEM - POWER SEAT CONTROL SYSTEM POWER SEAT CONTROL SYSTEM PARTS LOCATION Fuse Block POWER Fuse Lumber Support Motor Reclining Motor Rear Vertical Motor Reclining Motor Front Vertical Motor Power Seat Switch Slide Motor Lumber Support Switch Rear Vertical Motor Power Seat Switch Slide Motor...
  • Page 301 BE-22 BODY ELECTRICAL SYSTEM - POWER SEAT CONTROL SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
  • Page 302 BE-23 BODY ELECTRICAL SYSTEM - POWER SEAT CONTROL SYSTEM POWER SEAT SWITCH POWER SEAT SWITCH INSPECTION (DRIVER'S SIDE) CONTINUITY Inspect the switch continuity between terminals. If continuity is not as specified, replace the switch.
  • Page 303 BE-24 BODY ELECTRICAL SYSTEM - POWER SEAT CONTROL SYSTEM (PASSENGER'S SIDE) CONTINUITY Inspect the switch continuity between terminals. If continuity is not as specified, replace the switch.
  • Page 304 BE-25 BODY ELECTRICAL SYSTEM - POWER SEAT CONTROL SYSTEM POWER SEAT MOTOR SLIDE MOTOR INSPECTION MOTOR OPERATION Connect the positive ( + ) lead from the battery to ter- minal 1 and the negative ( —) lead to terminal 2, check that the motor turns counterclockwise.
  • Page 305 BE-26 BODY ELECTRICAL SYSTEM - POWER SEAT CONTROL SYSTEM Reverse the polarity, check that the seat cushion begins to descend within approximately 60 seconds. If operation is not as specified, replace the motor. REAR VERTICAL MOTOR INSPECTION MOTOR OPERATION Connect the positive ( + ) lead from the battery to ter- minal 2 and the negative ( —) lead to terminal 1, check that the motor turns counterclockwise.
  • Page 306 BE-27 BODY ELECTRICAL SYSTEM - POWER SEAT CONTROL SYSTEM MOTOR OPERATION PASSENGER' S SEAT Connect the positive ( + ) lead from the battery to ter- minal 1 and the negative ( —) lead to terminal 2, check that the motor turns counterclockwise. Reverse the polarity, check that the motor turns clockwise.
  • Page 307 BE-28 BODY ELECTRICAL SYSTEM - POWER SEAT CONTROL SYSTEM LUMBAR SUPPORT MOTOR INSPECTION MOTOR OPERATION Connect the positive ( + ) lead from the battery to ter- minal 1 and the negative ( —) lead to terminal 2, check that the lumbar support moves release side. Reverse the polarity, check that the lumbar support moves forward.

  • Page 308: Cruise Control System

    BE-29 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM PARTS LOCATION...
  • Page 309 BE-30 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM CONNECTOR DIAGRAMS...

  • Page 310: System Description

    BE-31 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM SYSTEM DESCRIPTION • When the ignition switch is turned ON, current flows from the battery to terminal 14 of the cruise control (CC ECU. • Terminal 13 of the CC ECU is always grounded. Basic Operation HINT: For all explanations below, the ignition switch is in the ON position.
  • Page 311 BE-32 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM DIAGNOSIS SYSTEM Output of Diagnostic Code READ DIAGNOSTIC CODE (Type A) Turn the ignition switch on. Turn the control switch to SET or RESUME position and keep it there. After pushing the main switch ON, keep the SET or RESUME switch ON for 3 seconds.
  • Page 312 BE-33 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM (Type B) If while driving with the cruise control on, the system is canceled by a malfunction in either the actuator, speed sensor or speed control switch circuit, the cruise control indicator light "CRUISE" will blink 5 times. While stopped, connect terminals (3) and Tc (11) of the check connector.
  • Page 313 BE-34 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM TROUBLESHOOTING You will find the source of the trouble more easily by properly using the table shown below. In this table, the numbers indicate the order of priority of the causes of trouble. Check each part in the order shown.
  • Page 314 BE-35 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM POWER SOURCE CIRCUIT HINT: While carrying out the following inspection, make certain that the connectors and terminals are pro- perly connected.
  • Page 315 BE-36 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM CRUISE CONTROL INDICATOR CIRCUIT HINT: While carrying out the following inspection, make certain that the connectors and terminals are pro- perly connected.
  • Page 316 BE-37 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM CONTROL SWITCH CIRCUIT HINT: While carrying out the following inspection, make certain that the connectors and terminals are pro- perly connected.
  • Page 317 BE-38 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM ACTUATOR CIRCUIT HINT: While carrying out the following inspection, make certain that connectors and terminals are proper- ly connected.
  • Page 318 BE-39 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM...
  • Page 319 BE-40 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM SPEED SENSOR CIRCUIT HINT: While carrying out the following inspection, make certain that the connectors and terminals are pro- perly connected.
  • Page 320 BE-41 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM STOP LIGHT SWITCH CIRCUIT HINT: While carrying out the following inspection, make certain that the connectors and terminals are pro- perly connected.
  • Page 321 BE-42 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM...
  • Page 322 BE-43 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM PARKING BRAKE SWITCH CIRCUIT HINT: While carrying out the following inspection, make certain that the connectors and terminals are pro- perly connected.
  • Page 323 BE-44 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM NEUTRAL START SWITCH CIRCUIT HINT: While carrying out the following inspection, make certain that the connectors and terminals are pro- perly connected. ECT SOLENOID No.2 CIRCUIT (with A/T) HINT: While carrying out the following inspection, make certain that the connectors and terminals are pro- perly connected.
  • Page 324 BE-45 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM IDL SIGNAL CIRCUIT (w/ 1FZ-FE Engine) HINT: While carrying out the following inspection, make certain that the connectors and terminals are pro- perly connected.
  • Page 325 BE-46 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM Cruise Control ECU Circuit INSPECT ECU CIRCUIT Disconnect connector and inspect connector on wire harness side as shown in the chart. If circuit is as specified, try another ECU.
  • Page 326 BE-47 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM CONTROL SWITCH INSPECTION INSPECT SWITCH If the continuity is not as specified, replace the control switch. STOP LIGHT SWITCH INSPECTION INSPECT SWITCH If continuity is not as specified, replace the stop light switch. NEUTRAL START SWITCH INSPECTION See page AT section THROTTLE POSITION SWITCH INSPECTION...
  • Page 327 BE-48 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM CRUISE CONTROL ACTUATOR INSPECTION INSPECT ACTUATOR (Magnet Clutch) Check that the arm moves smoothly by hand. (b) Connect the positive ( + ) lead from the battery to ter- minal 5 and the negative ( —) lead to terminal 4. (magnet clutch turned ON) (c) Check that the arm does not move by hand.
  • Page 328 BE-49 BODY ELECTRICAL SYSTEM - CRUISE CONTROL SYSTEM (b) When the arm is moving from the closed to open position, check that resistance between terminals 2 and 3 in- creases from approx. 0.5 to 1.7 If operation is not as specified, replace the motor. CONTROL LINK ASSEMBLY ADJUSTMENT ADJUST CONTROL LINK ASSEMBLY Connect the positive ( + ) lead from the battery to ter-...
  • Page 329 BE-50 BODY ELECTRICAL SYSTEM - EXTRA (SUB) TANK SYSTEM EXTRA (SUB) TANK SYSTEM PARTS LOCATION...
  • Page 330 BE-51 BODY ELECTRICAL SYSTEM - EXTRA (SUB) TANK SYSTEM...
  • Page 331 BODY ELECTRICAL SYSTEM - EXTRA (SUB) TANK SYSTEM TROUBLESHOOTING First use the diagnosis system to check for malfunctions. Repair any malfunctions found. Then check for malfunction in the parts shown in the table below. The most likely causes of malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.

  • Page 332: Fuel Pump

    BE-53 BODY ELECTRICAL SYSTEM - EXTRA (SUB) TANK SYSTEM FUEL PUMP INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 1 of the connector, and the negative ( —) lead to terminal 2. Check that the fuel pump operates. NOTICE: •...
  • Page 333 BE-54 BODY ELECTRICAL SYSTEM - EXTRA (SUB) TANK SYSTEM FUEL LEVEL SWITCH INSPECT FUEL LEVEL SWITCH (Continuity) FZJ7O type (Main Tank) FZJ7O type (Extra Tank) FZJ80 type (Main Tank) FZJ80 type (Sub Tank) If continuity is not as specified, replace the switch.
  • Page 334 BE-55 BODY ELECTRICAL SYSTEM - EXTRA (SUB) TANK SYSTEM FUEL SENDER GAUGE INSPECT FUEL SENDER GAUGE Measure the resistance. FZJ8O type (Main tank) FZJ7O type (Main tank) FUEL SOLENOID VALVE INSPECT FUEL SOLENOID VALVE Check that air flows out port A when battery voltage is applied across the terminals.
  • Page 335 BE-56 BODY ELECTRICAL SYSTEM - EXTRA (SUB) TANK SYSTEM FUEL PUMP CONTROL ECU FUEL PUMP CONTROL ECU INSPECTION ECU CIRCUIT Disconnect the connector from the ECU and inspect the connector on the wire harness side as shown in the chart. If circuit is as specified, try other ECU.
  • Page 336 BE-57 BODY ELECTRICAL SYSTEM - EXTRA (SUB) TANK SYSTEM DIAGNOSIS SYSTEM READ DIAGNOSTIC CODE When there is a malfunction in the extra (sub) tank system, the warning light light up. OUTPUT OF DIAGNOSTIC CODE Turn the ignition switch ON. Connect terminals T and E of the check connector.
  • Page 337 BE-58 BODY ELECTRICAL SYSTEM - EXTRA (SUB) TANK SYSTEM READ TEST CODE The indicator light outputs the indication codes shown below in conformity with signals input or output by the extra (sub) tank system. OUT PUT OF TEST CODE Turn the ignition switch ON. Connect terminals T and E of the check connector.

  • Page 338: Satellite Navigation System

    BE-59 BODY ELECTRICAL SYSTEM - SATELLITE NAVIGATION SYSTEM SATELLITE NAVIGATION SYSTEM PARTS LOCATION...

  • Page 339: Wiring Diagrams

    BE-60 BODY ELECTRICAL SYSTEM - SATELLITE NAVIGATION SYSTEM WIRING DIAGRAMS...
  • Page 340 BE-61 BODY ELECTRICAL SYSTEM - SATELLITE NAVIGATION SYSTEM DIAGNOSIS SYSTEM OUTPUT OF DIAGNOSTIC CODE READ DIAGNOSTIC CODE DO THE FOLLOWING STEPS TO READ DIAGNOSTIC CODE Turn the ignition switch ACC or ON. Push " N A V I " or " S E T " . Push "...

  • Page 341: Air Conditioning System

    AC-1 AIR CONDITIONING SYSTEM REFER TO FOLLOWING REPAIR MANUALS: Manual Name Pub. No. RM183E • Land Cruiser (Hardtop and Canvas Top) Chassis and Body Repair Manual RM184E • Land Cruiser (Station Wagon) Chassis and Body Repair Manual • Land Cruiser (Hardtop, RM290E Canvas Top &...
  • Page 342 AC-2 AIR CONDITIONING SYSTEM - DESCRIPTION (Hardtop & Canvas Top) DESCRIPTION ELECTRICAL WIRING DIAGRAM...
  • Page 343 AC-3 AIR CONDITIONING SYSTEM - DESCRIPTION...
  • Page 344 AC-4 AIR CONDITIONING SYSTEM - DESCRIPTION...
  • Page 345 AC-5 AIR CONDITIONING SYSTEM - DESCRIPTION - MEMO...
  • Page 346 AC-6 AIR CONDITIONING SYSTEM - DESCRIPTION...
  • Page 347 AC-7 AIR CONDITIONING SYSTEM - DESCRIPTION...
  • Page 348 AC-8 AIR CONDITIONING SYSTEM - DESCRIPTION...
  • Page 349 AC-9 AIR CONDITIONING SYSTEM - DESCRIPTION...
  • Page 350 AC-10 AIR CONDITIONING SYSTEM - DRIVE BELT DRIVE BELT ON-VEHICLE INSPECTION INSPECT DRIVE BELT TENSION Drive belt tension at 10 kg (22.0 Ib, 98N): FZ Series Engine New belt 5 - 7 mm (0.20 - 0.28 in.) Used belt 7 - 9.5 mm (0.28 - 0.37 in.)
  • Page 351 AC-11 AIR CONDITIONING SYSTEM - REFRIGERATION LINES REFRIGERATION LINES TIGHTENING...
  • Page 352 AC-12 AIR CONDITIONING SYSTEM - COMPRESSOR COMPRESSOR COMPRESSOR REMOVAL RUN ENGINE AT IDLE SPEED WITH A/C ON FOR TEN MINUTES STOP ENGINE DISCONNECT NEGATIVE CABLE FROM BATTERY DISCONNECT CONNECTOR FROM MAGNET CLUTCH RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM DISCONNECT TWO HOSES FROM COMPRESSOR SER- VICE VALVES Cap the open fittings immediately to keep the moisture and dust out of the system.
  • Page 353 AC-13 AIR CONDITIONING SYSTEM - COMPRESSOR LOOSEN IDLE PULLEY LOCK NUT AND COMPRESSOR DRIVE BELT REMOVE COMPRESSOR Remove the four bolts and pull the compressor upward. MAGNET CLUTCH DISASSEMBLY...

  • Page 354: Cooling Unit

    AC-14 AIR CONDITIONING SYSTEM - COOLING UNIT COOLING UNIT COOLING UNIT DISASSEMBLY FZ Series Engine Packing Rear Cooler Relay Wire Harness Upper Unit Case Packing Magnet Clutch Relay Expansion Valve Clip A/C Amplifier Grommet Drain Hose Thermistor Blower Speed Control Relay Packing (Push Type A/C Control...
  • Page 355 AC-15 AIR CONDITIONING SYSTEM - AIR CONDITIONER AMPLIFIERS AIR CONDITIONER AMPLIFIER (Dual A / C : 1FZ-F Engine) INSPECT AMPLIFIER CIRCUIT Disconnect the amplifier and inspect the connector on the wire harness side as shown in the chart below. Test conditions: (1) Ignition switch: ON (2) Temperature control lever: MAX COOL...
  • Page 356 AC-16 AIR CONDITIONING SYSTEM - AIR CONDITIONER AMPLIFIERS (Dual A/C : 1FZ-FE Engine) INSPECT AMPLIFIER CIRCUIT Disconnect the amplifier and inspect the connector on the wire harness side as shown in the chart below. Test conditions: (1) Ignition switch: ON (2) Temperature control lever: MAX COOL (3) Blower switch: HI If circuit is as specified, replace the amplifier.
  • Page 357 AC-17 AIR CONDITIONING SYSTEM - AIR CONDITIONER AMPLIFIERS - MEMO -...
  • Page 358 AC-18 AIR CONDITIONING SYSTEM - DESCRIPTION (Station Wagon) DESCRIPTION ELECTRICAL WIRING DIAGRAM...
  • Page 359 AC-19 AIR CONDITIONING SYSTEM - DESCRIPTION...
  • Page 360 AC-20 AIR CONDITIONING SYSTEM - DESCRIPTION...
  • Page 361 AC-21 AIR CONDITIONING SYSTEM - DESCRIPTION...
  • Page 362 AC-22 AIR CONDITIONING SYSTEM - DRIVE BELT DRIVE BELT ON-VEHICLE INSPECTION INSPECT DRIVE BELT TENSION Drive belt tension at 10 kg (22.0 Ib, 98 N): FZ Series Engine New belt 5 - 7 mm (0.20 - 0.28 in.) Used belt 7 - 7.5 mm (0.28 - 0.37 in.) (Reference) Using SST, check the drive belt tension.
  • Page 363 AC-23 AIR CONDITIONING SYSTEM - COMPRESSOR COMPRESSOR COMPRESSOR REMOVAL RUN ENGINE AT IDLE SPEED WITH A/C ON FOR TEN MINUTES STOP ENGINE DISCONNECT NEGATIVE CABLE FROM BATTERY DISCONNECT CONNECTOR FROM MAGNET CLUTCH RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM DISCONNECT TWO HOSES FROM COMPRESSOR SER- VICE VALVES Cap the open fittings immediately to keep the moisture and dust out of the system.
  • Page 364 AC-24 AIR CONDITIONING SYSTEM - COMPRESSOR LOOSEN IDLE PULLEY LOCK NUT AND COMPRESSOR DRIVE BELT REMOVE COMPRESSOR Remove the four bolts and pull the compressor upward. MAGNET CLUTCH DISASSEMBLY...
  • Page 365 AC-25 AIR CONDITIONING SYSTEM - AIR CONDITIONER AMPLIFIER AIR CONDITIONER AMPLIFIER INSPECT AMPLIFIER CIRCUIT Disconnect the amplifier and inspect the connector on the wire harness side as shown in the chart below. Test conditions: (1) Ignition: ON (2) Temperature control lever: MAX.

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