TOYOTA T100 1996 Factory Service Manual

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Front Propeller Shaft
Rear Propeller Shaft
PR01Q−01
PR0036
Front PR−14
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (4WD)
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
When removing or installing any part, make sure that each joint
is facing to the correct direction, as shown in the illustration be-
low.
1. Frsont:
INSERT SLEEVE YOKE INTO FRONT PROPELLER
SHAFT
(a) Apply MP grease to the propeller shaft spline and sleeve
yoke sliding surface.
(b) Align the matchmarks on the sleeve yoke and propeller
shaft.
(c) Insert the sleeve yoke into the propeller shaft.
2. Rear:
INSTALL CENTER SUPPORT BEARING ON INTER-
MEDIATE SHAFT
HINT:
Install the center support bearing in the direction, as shown.

Downloaded from www.Manualslib.com manuals search engine PR0011
Matchmarks
PR0034
SST
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (4WD)
PR−15
1996 TOYOTA T100 (RM449U)
3. Rear:
INSTALL FLANGE ON INTERMEDIATE SHAFT
(a) Coat the splines of the intermediate shaft with MP grease.
(b) Place the flange on the shaft and align the matchmarks.
HINT:
If replacing either the center flange or intermediate shaft, reas-
semble it so that the front side flange yoke of the intermediate
shaft and the rear side flange yoke of the propeller shaft facing
in the same direction.
(c) Using SST to hold the flange, press the bearing into posi-
tion by tightening down a new nut.
SST 09330−00021
Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
(d) Loosen the nut.
(e) Torque the nut again.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(f) Using a hammer and punch, stake the nut.
4. Rear:
INSTALL PROPELLER SHAFT
(a) Align the matchmarks on the flanges and connect the
flanges with 4 bolts, washers and nuts.
HINT:
If replacing either the center flange or intermediate shaft, reas-
sembly it so that the front side flange yoke of the intermediate
shaft and the rear side flange yoke of the propeller shaft are fac-
ing in the same direction.
(b) Torque the bolts.
Torque: 76 N·m (780 kgf·cm, 56 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine PR080−01
R04437
Matchmarks
R04440
Matchmarks
Z04758
A
A B
R15508Matchmarks PR−16
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (4WD)
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL FRONT PROPELLER SHAFT:
(a) Align the matchmarks on the propeller shaft and differen-
tial flanges, and connect the flanges with the 4 nuts and
washers.
(b) Torque the 4 nuts.
Torque: 74 N·m (750 kgf·cm,54 ft·lbf)
(c) Align the matchmarks on the propeller shaft and transfer
flanges, and connect the flanges with the 4 bolts, washers
and nuts.
(d) Torque the 4 bolts.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
(e) Install the propeller shaft dust cover with the 3 bolts.
Torque:
A bolt: 36 N·m (370 kgf·cm, 27 ft·lbf)
B bolt: 23 N·m (230 kgf·cm, 17 ft·lbf)
(f) M/T:
Install the propeller shaft No.2 dust cover with the 2 bolts
and nuts.
Torque:
Bolt: 17 N·m (175 kgf·cm, 13 ft·lbf)
Nut: 13 N·m (135 kgf·cm, 10 ft·lbf)
2. INSTALL REAR PROPELLER SHAFT
(a) Align the matchmarks on the propeller shaft and transfer
flanges, and connect the flanges with 4 nuts and wash-
ers.
(b) Torque the 4 nuts.
Torque: 76 N·m (780 kgf·cm, 56 ft·lbf)
(c) Temporarily install the center support bearing with 2
mount bolts finger tight.
HINT:
Make sure the bearing is installed with facing the drain hole
downwards.
(d) Align the matchmarks on the flanges, and connect the
flanges with the 4 bolts, washers and nut.
(e) Torque the 4 bolts.
Torque: 76 N·m (780 kgf·cm, 56 ft·lbf)

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Bracket Center
Line
90
Shaft Axial
Direction
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (4WD)
PR−17
1996 TOYOTA T100 (RM449U)
3. ADJUST CENTER SUPPORT BEARING
HINT:
With the vehicle unladen, adjust the center support bear-
ing to keep the intervals, as shown.
At the same condition, check the center line in the axial
direction. Adjust the bearing if necessary.
Check that the center line of the center bearing is set to
the center line of the bracket when the vehicle is unladen.
Adjust the bracket if necessary.
(a) Torque the 2 bolts.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
(b) Install propeller shaft protector with 4 bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

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Matchmarks
MatchmarksPR01S−01
Z16099
PR0019
SST
A
R04419
SST PR−18
− PROPELLER SHAFTSPIDER BEARING
1436 Author: Date:
1996 TOYOTA T100 (RM449U)
SPIDER BEARING
REPLACEMENT
1. PLACE MATCHMARKS ON SHAFT AND YOKE
2. REMOVE SNAP RING
(a) Using a brass bar and hammer, slightly tap in the bearing
outer race.
(b) 2WD (TMC−made) and 4WD:
Using 2 screwdrivers, remove the 4 snap rings from the
grooves.
(c) 2WD (DANA−made):
Using a long nosed plier, remove the 4 snap rings from the
grooves.
3. REMOVE SPIDER BEARING
(a) Using SST, push out the bearing from the flange.
SST 09332−25010
HINT:
Sufficiently raise the part indicated by ”A” so that it does not
come into contact with the bearing.
(b) Clamp the bearing outer race in a vise and tap off the
flange with a hammer.
HINT:
Remove the bearing on the opposite side in the same proce-
dure.
(c) Install the 2 removed bearing outer races to the spider.
(d) Using SST, push out the bearing from the yoke.
SST 09332−25010
(e) Clamp the outer bearing race in a vise and tap off the yoke
with a hammer.
HINT:
Remove the bearing on the opposite side in the same proce-
dure.

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Color
Bearing
CapDrill Mark
Drill MarkYoke
Z00735
PR0027
SST
PR0028
R16052
− PROPELLER SHAFTSPIDER BEARING
PR−19
1437 Author: Date:
1996 TOYOTA T100 (RM449U)
4. SELECT SPIDER BEARING
Select the appropriate bearing according to the existence of
drill mark on the yoke.
YokeBearing
With drill markWith color mark (Red)
No drill markNo color mark
5. INSTALL SPIDER BEARING
(a) Apply MP grease to the spider and bearings.
HINT:
Be careful not to apply too much grease.
(b) Align the matchmarks on the yoke and shaft.
(c) Fit a new spider into the yoke.
(d) Using SST, install a new bearing on the spider.
SST 09332−25010
(e) Using SST, adjust both bearings so that the snap ring
grooves are at maximum and equal in width.
6. INSTALL SNAP RINGS
(a) Install 2 new snap rings of equal thickness which will allow
0 − 0.05 mm (0 − 0.0020 in.) axial play.
HINT:
Do not reuse the snap rings.

Downloaded from www.Manualslib.com manuals search engine R16053
R04428
PR−20
− PROPELLER SHAFTSPIDER BEARING
1438 Author: Date:
1996 TOYOTA T100 (RM449U)
2WD (TMC−made) and 4WD:
ColorMarkThickness mm (in.)
−12.100 − 2.150
(0.0827 − 0.0846)
−22.150 − 2.200
(0.0846 − 0.0866)
−32.200 − 2.250
(0.0866 − 0.0886)
Brown−2.250 − 2.230
(0.0886 − 0.0906)
Blue−2.300 − 2.350
(0.0906 − 0.0925)
−62.350 − 2.400
(0.0925 − 0.0945)
−72.400 − 2.450
(0.0945 − 0.0965)
−82.450 − 2.500
(0.0965 − 0.0984)
2WD (DANA−made):
ColorThickness mm (in.)
Green1.384 (0.0545)
Red1.435 (0.0565)
Black1.486 (0.0585)
Copper1.511 (0.0595)
Silver1.537 (0.0605)
Yellow1.588 (0.0625)
Blue1.638 (0.0645)
(b) Using a hammer, tap the yoke until there is no clearance
between the bearing outer race and snap ring.
7. CHECK SPIDER BEARING
(a) Check that the spider bearing moves smoothly.
(b) Check the spider bearing axial play.
Bearing axial play: Less than 0.05 mm (0.0020 in.)
HINT:
Install new spider bearings on the flange side in the procedure
described above.

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SPIDER GREASE FITTING ASSEMBLY DIRECTION
FOR 4WD FRONT PROPELLER SHAFT
SPIDER GREASE FITTING ASSEMBLY DIRECTION
FOR 4WD REAR PROPELLER SHAFTNo.1
Sleeve YokeSleeve Yoke
No.1
No.1
No.4, No.3, No.2, Sleeve Yoke
No.5
No.2
No.3 No.4
No.5
Sleeve YokeNo.1 The figure at left shows the locations
of the grease fittings as seen from the
rear.
The figure at left shows the locations
of the grease fittings as seen from the
rear.
− PROPELLER SHAFTSPIDER BEARING
PR−21
1439 Author: Date:
1996 TOYOTA T100 (RM449U)
HINT:
When replacing the rear propeller shaft spider on 4WD vehicle,
be sure that the grease fitting assembly hole is facing in the
direction shown in the illustration.

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TROUBLESHOOTING SA-1

TIRE AND WHEEL (2WD) SA-3
TIRE AND WHEEL (4WD) SA-5
FRONT WHEEL ALIGNMENT (2WD) SA-7
FRONT WHEEL ALIGNMENT (4WD) SA-10
FRONT AXLE HUB (2WD) SA-15
FRONT AXLE HUB (4WD) SA-22
FRONT WHEEL HUB BOLT (2WD) SA-27
STEERING KNUCKLE (4WD) SA-28
FRONT DRIVE SHAFT (4WD) SA-36
FRONT DIFFERENTIAL REAR OIL
SEAL (4WD) SA-42
FRONT DIFFERENTIAL CARRIER
(4WD) SA-45
A.D.D. CONTROL SYSTEM SA-69
FRONT SHOCK ABSORBER (2WD) SA-72
FRONT SHOCK ABSORBER (4WD) SA-77
FRONT TORSION BAR SPRING (2WD) SA-82
FRONT TORSION BAR SPRING (2WD) SA-85
FRONT STRUT BAR (2WD) SA-88
FRONT UPPER SUSPENSION ARM
(2WD) SA-91
FRONT UPPER SUSPENSION ARM
(4WD) SA-95
FRONT LOWER SUSPENSION ARM
(2WD) SA-99
FRONT LOWER SUSPENSION ARM
(4WD) SA-103

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FRONT UPPER BALL JOINT (2WD) SA-107
FRONT UPPER BALL JOINT (4WD) SA-111
FRONT LOWER BALL JOINT (2WD) SA-115
FRONT LOWER BALL JOINT (4WD) SA-119
FRONT STABILIZER BAR (2WD) SA-123
FRONT STABILIZER BAR (4WD) SA-126
REAR AXLE SHAFT SA-129
REAR WHEEL HUB BOLT SA-136
REAR DIFFERENTIAL CARRIER SA-137
REAR SHOCK ABSORBER SA-155
REAR LEAF SPRING SA-160