Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - AXLE AND DIFFERENTIAL

Using a 5 mm hexagon socket wrench, loosen the lower and upper chamber shutter valves of the stabilizer control with accumulator housing 2.0 to 3.5 turns.

Rear Axle Hub Bolt - Replacement. AXLE AND DIFFERENTIAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

NOTICE:

When loosening a shutter valve, make sure that the end protrudes 2 to 3.5 mm (0.0787 to 0.137 in.) from the surface of the block, and do not turn the shutter valve any further.

Do not remove the shutter valves.

3. REMOVE REAR WHEEL LH

4. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH

Remove the 2 bolts and disconnect the rear disc brake cylinder.

NOTICE:

Do not twist or bend the flexible hose.

Do not disconnect the flexible hose from the disc brake cylinder.

5. REMOVE REAR DISC LH

Put matchmarks on the rear disc and axle hub if planning to reuse the disc.

Turn the shoe adjuster as shown in the illustration until the disc turns freely, and then remove the disc.

6. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING LH

Using SST, remove the return spring.

SST
09703-30011

7. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY LH

Using SST, remove the shoe hold down spring cup, compression spring and shoe hold down spring pin.

SST
09718-00011

Disconnect the tension spring from the No. 1 parking brake shoe.

Remove the No. 1 parking brake shoe and shoe adjuster screw set.

8. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY LH

Using SST, remove the shoe hold down spring cup, compression spring and shoe hold down spring pin.

SST
09718-00011

Remove the No. 2 parking brake shoe.

9. REMOVE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH

Disconnect the No. 3 parking brake cable from the parking brake shoe lever.

Remove the parking brake shoe lever.

10. REMOVE REAR AXLE HUB BOLT LH

Using SST and a screwdriver or equivalent to hold the axle hub, remove the hub bolt.

SST
09650-17011

NOTICE:

Do not deform the oil deflector.

Make sure to align the notch of SST with the flange of the oil deflector.

11. INSTALL REAR AXLE HUB BOLT LH

Temporarily install a washer and hub nut to a new hub bolt as shown in the illustration.

NOTICE:

Install a hub nut to prevent damage to the hub bolt.

Using a screwdriver or equivalent to hold the hub, turn the hub nut until the bottom surface of the hub bolt head touches the axle hub.

Remove the washer and hub nut.

NOTICE:

Do not damage the threads of the hub bolt.

12. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH

Apply high temperature grease to the parking brake anchor block.

Install the parking brake shoe lever to the No. 3 parking brake cable.

NOTICE:

Be carefully to distinguish between the parking brake shoe lever RH and LH.

13. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH

Apply high temperature grease to the areas of the backing plate that contact the shoe.

Using SST, install the No. 2 parking brake shoe with the shoe hold down spring pin, compression spring and shoe hold down spring cup.

SST
09718-00011

14. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH

Apply high temperature grease to the areas of the backing plate that contact the shoe.

Apply high temperature grease to the thread and all joining areas of the parking brake shoe adjuster screw set.

Set the No. 1 parking brake shoe and shoe adjuster screw set in place.

Connect the tension spring.

Using SST, install the shoe hold down spring pin, compression spring and shoe hold down spring cup.

SST
09718-00011

15. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING LH

Using SST, install the shoe return spring.

SST
09703-30011

16. CHECK PARKING BRAKE INSTALLATION

Check that each part is installed properly.

Rear Axle Hub Bolt - Replacement. AXLE AND DIFFERENTIAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

17. INSTALL REAR DISC LH

Align the matchmarks, and then install the rear disc.

HINT:

When replacing the rear disc with a new one, select the installation position where the rear disc has the minimum runout.

18. ADJUST PARKING BRAKE SHOE CLEARANCE

Completely release the parking brake lever.

Loosen the adjusting nut to completely release the parking brake cable.

Temporarily install the hub nuts.

Remove the hole plug.

Insert an adjustment tool into the adjustment hole of the disc. Rotate the adjustment wheel in the "X" direction until the shoes are locked. Then rotate the adjustment wheel in the "Y" direction 8 notches.

Check that the disc can be rotated lightly. If not, rotate the adjustment wheel in the "Y" direction and check again.

Install the hole plug.

Remove the hub nuts.

Turn the adjusting nut until the parking brake lever travel becomes correct.

Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):
5 to 7 clicks

Operate the parking brake lever 3 to 4 times, and check the parking brake lever travel.

Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):
5 to 7 clicks

Check whether the parking brake drags or not.

When operating the parking brake lever, check that the brake warning light comes on.

Standard Condition:
The brake warning light always illuminates at the first click.

19. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH

Connect the rear disc brake cylinder and install 2 new bolts.

Torque:
95 N*m{ 969 kgf*cm, 70 ft.*lbf}

NOTICE:

Do not twist the flexible hose.

Make sure that the bolts are free from damage and foreign matter.

Do not overtighten the bolts.

20. INSTALL REAR WHEEL LH

Torque:
for Aluminum Wheel:
131 N*m{ 1336 kgf*cm, 97 ft.*lbf}
for Steel Wheel:
209 N*m{ 2131 kgf*cm, 154 ft.*lbf}

21. CHECK PARKING BRAKE LEVER TRAVEL

Fully pull the parking brake lever to engage the parking brake.

Release the lever to disengage the parking brake.

Slowly pull the parking brake lever all the way, and count the number of clicks.

Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):
5 to 7 clicks

If the parking brake lever travel is not as specified, adjust the parking brake shoe clearance and parking brake lever travel.

22. ADJUST PARKING BRAKE LEVER TRAVEL

Completely release the parking brake lever.

Loosen the adjusting nut to completely release the parking brake cable.

Temporarily install the hub nuts.

Remove the hole plug.

Check that the disc can be rotated lightly. If not, rotate the adjustment wheel in the "Y" direction and check again.

Install the hole plug.

Remove the hub nuts.

Turn the adjusting nut until the parking brake lever travel becomes correct.

Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):
5 to 7 clicks

Operate the parking brake lever 3 to 4 times, and check the parking brake lever travel.

Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf):
5 to 7 clicks

Check whether the parking brake drags or not.

When operating the parking brake lever, check that the brake warning light comes on.

Standard Condition:
The brake warning light always illuminates at the first click.

23. MEASURE VEHICLE HEIGHT (w/ KDSS)

NOTICE:

Perform the inspection on a level surface.

Ensure that the wheels are on the ground and facing straight ahead.

Perform the inspection with the vehicle load completely on the suspension.

HINT:

Perform this step with the fuel tank full.

If there are any parts installed to the vehicle which place any unbalanced load on the left or right side of the vehicle, remove them.

Set the tire pressure to the specified value(s) ().

Bounce the vehicle to stabilize the suspension.

Measure the distance from the ground to the top of the bumper and calculate the difference in the vehicle height between left and right. Perform this procedure for both the front and rear wheels.

Height difference of left and right sides:
15 mm (0.591 in.) or less

HINT:

If not as specified, perform the vehicle tilt calibration.

24. CLOSE STABILIZER CONTROL WITH ACCUMULATOR HOUSING SHUTTER VALVE (w/ KDSS)

NOTICE:

Perform the inspection on a level surface.

Ensure that the wheels are on the ground and facing straight ahead.

Perform the inspection with the vehicle load completely on the suspension.

HINT:

Perform this step with the fuel tank full.

If there are any parts installed to the vehicle which place any unbalanced load on the left or right side of the vehicle, remove them.

Using a 5 mm hexagon socket wrench, tighten the lower and upper chamber shutter valves of the stabilizer control with accumulator housing.

Torque:
14 N*m{ 143 kgf*cm, 10 ft.*lbf}

25. INSTALL STABILIZER CONTROL VALVE PROTECTOR (w/ KDSS)

Install the valve protector with the 3 bolts.

Torque:
18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Attach the clamp, and connect the connector to the valve protector.