TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine Q02464
Push Rod Play Adjust Point
Pedal Height
Adjust Point
Pedal Height
Push Rod
PlayCL027−01
CL0102Pedal Freeplay CL−2
− CLUTCHCLUTCH PEDAL
1237 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH PEDAL
INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from floor panel:
154.6 − 164.6 mm (6.087 − 6.480 in.)
Pedal height from asphalt sheet:
Extra Cab (4WD): 150.1 − 160.1 mm (5.909 − 6.303 in.)
Others: 153.1 − 163.1 mm (6.027 − 6.421 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD
PLAY ARE CORRECT
Push in on the pedal until the beginning of clutch resis-
tance is felt.
Pedal freeplay: 5.0 − 15.0 mm (0.197 − 0.591 in.)
Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0 − 5.0 mm (0.039 − 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. CHECK CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears contact.

Downloaded from www.Manualslib.com manuals search engine CL0512
25 mm (0.98 in.) or more
Release
Point
Full Stroke
End Position
Q02465
Clutch
Start Switch
Q00617
8 ± 0.5 mm
(0.31 ± 0.020 in.)
− CLUTCHCLUTCH PEDAL
CL−3
1238 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance not as specified, perform the following operation.
Check pedal height.
Check push rod play and pedal freeplay.
Bleed the clutch line.
Check the clutch cover and disc.
6. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch ped-
al is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, replace the clutch start switch.
7. CHECK CONTINUITY OF CLUTCH START SWITCH
Check the continuity between terminals when the switch is ON
and OFF.
Switch positionCondition
ON (pushed)Continuity
OFF (free)No Continuity
If continuity is not as specified, replace the switch.

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No continuity
Z17111
No continuity
Z17112No continuity
CL0363
Continuity
CL0364
No continuity CL−4
− CLUTCHCLUTCH PEDAL
1239 Author: Date:
1996 TOYOTA T100 (RM449U)
8. CHECK CONTINUITY OF CLUTCH START CANCEL
SWITCH
(a) Check that there is no continuity when connecting the
positive (+) lead from the ohmmeter to terminal 2 and the
negative (−) lead to terminal 1.
(b) Check that there is no continuity when connecting the
positive (+) lead from the ohmmeter to terminal 3 and the
negative (−) lead to terminal 1.
(c) Check the there is no continuity between terminals 2 and
3.
If continuity is not as specified, replace the clutch start cancel
switch.
9. CHECK OPERATION OF CLUTCH START CANCEL
SWITCH
(a) Connect positive (+) lead from the battery to terminal 3
and connect negative (−) lead to terminal 1.
(b) Check that there is no continuity when connecting the
positive (+) lead from the ohmmeter to terminal 2 and the
negative (−) lead to terminal 1.
(c) When pushing the switch, check that the indicator light
connect on and there is continuity between terminal 1 and
2.
(d) Check that there is no continuity between terminals 1 and
2 when disconnect the battery lead.
If continuity is not as specified, replace the clutch start cancel
switch.

Downloaded from www.Manualslib.com manuals search engine CL028−03
Q07730
Filler Cap
FloatClevis
Clip
Snap Ring
Push Rod
Pin
Lock Nut
Boot
Washer
Piston
Spring
 Non−reusable partClutch Line Master Cylinder Slotted Spring PinReservoir Tank
 Grommet
Body
− CLUTCHCLUTCH MASTER CYLINDER
CL−5
1240 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH MASTER CYLINDER
COMPONENTS

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Q02468
SST CL−6
− CLUTCHCLUTCH MASTER CYLINDER
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAW OUT FLUID WITH SYRINGE
2. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
3. REMOVE CLIP AND CLEVIS PIN
4. REMOVE MOUNTING NUTS AND PULL OUT MASTER
CYLINDER
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine CL02A−01
Q02469
Q02470
− CLUTCHCLUTCH MASTER CYLINDER
CL−7
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE RESERVOIR TANK
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the reservoir tank and grommet.
2. REMOVE PUSH ROD
Pull back the boot, and using snap ring pliers, remove the snap
ring.
3. REMOVE PISTON

Downloaded from www.Manualslib.com manuals search engine CL02B−01
Z08053
Q02471
Protrusion
1.5 − 3.5 mm
(0.059 − 0.138 in.) CL−8
− CLUTCHCLUTCH MASTER CYLINDER
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON INTO CYLINDER
3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING
4. INSTALL RESERVOIR TANK
(a) Install the reservoir tank and a new grommet.
(b) Using a pin punch and hammer, drive in the slotted spring
pin.

Downloaded from www.Manualslib.com manuals search engine CL02C−02
− CLUTCHCLUTCH MASTER CYLINDER
CL−9
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page CL−6).
HINT:
After installation, bleed system and adjust clutch pedal.

Downloaded from www.Manualslib.com manuals search engine CL02D−03
Q07554
3RZ−FE: 5VZ−FE:
Clutch Line
Bleeder Plug
Release
Cylinder BodyClutch LineBleeder PlugPush Rod
Release Cylinder BodyBoot
Piston
Spring
N·m (kgf·cm, ft·lbf) : Specified torque
CL−10
− CLUTCHCLUTCH RELEASE CYLINDER
1245 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH RELEASE CYLINDER
COMPONENTS

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Z17113
SST
Q06733
− CLUTCHCLUTCH RELEASE CYLINDER
CL−11
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-
INDER
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)