TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SA0FT−01
FA0786
SST
− SUSPENSION AND AXLESTEERING KNUCKLE (4WD)
SA−31
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE DUST COVER
Using a screwdriver and hammer, remove the dust cover from
the steering knuckle.
2. REMOVE STEERING KNUCKLE BUSHING
(a) Using SST, remove the steering knuckle outside bushing.
SST 09308−00010
(b) Using a brass bar and hammer, remove the steering
knuckle needle roller bearing and inside bushing.

Downloaded from www.Manualslib.com manuals search engine SA0FU−01
FA0735
SA−32
− SUSPENSION AND AXLESTEERING KNUCKLE (4WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT STEERING KNUCKLE
Using a dye penetrant, check the steering knuckle for cracks.

Downloaded from www.Manualslib.com manuals search engine SA0FV−02
W00456
SST
W00458
SST
Knuckle
Needle
Roller Bearing SSTThrust
Bushing
R04291
SST
− SUSPENSION AND AXLESTEERING KNUCKLE (4WD)
SA−33
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. INSTALL STEERING KNUCKLE BUSHING
(a) Using SST and a press, install a new steering knuckle out-
side bushing.
SST 09950−60010 (09951−00360),
09950−70010 (09951−07150)
HINT:
When installing the bushing to the spindle, make sure the flat
portion of the bushing is aligned with the spindle groove, as
shown in the illustration.
(b) Using SST and a press, install a new needle roller bear-
ing, as shown in the illustration.
SST 09950−60010 (09951−00360),
09950−70010 (09951−07150)
HINT:
Bearing must be installed with flat side which has I.D. and
part number facing outward.
Press the bearing in until the top surface of the bearing is
in approx. 2 − 3 mm (0.08 − 0.12 in.) inside the knuckle
surface.
(c) Using SST and a press, install a new thrust bushing.
SST 09950−60010 (09951−00500),
09950−70010 (09951−07150)
(d) Apply synthetic oil and lithium soap base chassis grease,
NLGI No.1 to the steering knuckle inner side of thrust
bushing.
2. INSTALL DUST DEFLECTOR TO STEERING
KNUCKLE
Using SST and a hammer, install a new dust deflector.
SST 09950−60020 (09951−00910),
09950−70010 (09951−07150)

Downloaded from www.Manualslib.com manuals search engine SA0FW−02
R04389
FA0781
Z03703
SA−34
− SUSPENSION AND AXLESTEERING KNUCKLE (4WD)
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL STEERING KNUCKLE
(a) Apply synthetic oil and lithium soap base chassis grease,
NLGI No.1 to the drive shaft.
(b) Push down the lower suspension arm and install the
steering knuckle.
NOTICE:
Be careful not to damage the oil seal and boot.
(c) Connect the lower ball joint to the steering knuckle, install
and torque the nut.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
(d) Install a new cotter pin.
(e) Connect the upper ball joint to the steering knuckle, install
and torque the 4 nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
(f) Install a new cotter pin.
(g) Install the spacer to the drive shaft.
(h) Using snap ring pliers, install the snap ring.
NOTICE:
If you replace the steering knuckle bushing, recheck the
drive shaft thrust clearance.
(i) Install the bolt in the drive shaft.
(j) Using a feeler gauge, measure the drive shaft thrust
clearance between the steering knuckle outside bushing
and spacer, by pulling the bolt and applying a load of 98
N (10 kgf, 22.0 lbf).
Front drive shaft thrust clearance:
Standard: 0.10 − 0.50 mm (0.0039 − 0.0197 in.)
If the clearance is not within specification, replace the spacer.
Spacer thickness
1.80 mm (0.0709 in.)2.25 mm (0.0886 in.)
2. CONNECT STABILIZER BAR TO LOWER
SUSPENSION ARM
(a) Connect the stabilizer bar to the lower suspension arm
with the bolt, 5 retainers, 4 cushions, collar and a new nut,
as shown in the illustration.
(b) Torque the nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine − SUSPENSION AND AXLESTEERING KNUCKLE (4WD)
SA−35
1996 TOYOTA T100 (RM449U)
3. CONNECT FRONT SHOCK ABSORBER TO LOWER
SUSPENSION ARM
Install the shock absorber, bolt, washer and nut to the lower
suspension arm.
Torque: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
4. INSTALL DUST COVER AND NEW OIL SEAL
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
5. INSTALL FRONT AXLE HUB AND BRAKE CALIPER
(See page SA−25)
6. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)
7. w/ ABS:
CHECK ABS SPEED SENSOR SIGNAL
(See page DI−321)

Downloaded from www.Manualslib.com manuals search engine SA0FX−02
SA−36
− SUSPENSION AND AXLEFRONT DRIVE SHAFT (4WD)
1475 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT DRIVE SHAFT (4WD)
COMPONENTS

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R04298
Matchmarks
− SUSPENSION AND AXLEFRONT DRIVE SHAFT (4WD)
SA−37
1996 TOYOTA T100 (RM449U)
REMOVAL
1. LOOSEN NUTS HOLDING FRONT DRIVE SHAFT
(a) Place matchmarks on the inboard joint tulip and side gear
shaft.
(b) Loosen the 6 nuts, with depressing the brake pedal.
Torque: 83 N·m (845 kgf·cm, 61 ft·lbf)
2. REMOVE FLANGE (See page SA−23)
3. REMOVE SNAP RING AND SPACER
Using a snap ring expander, remove the snap ring from the
drive shaft.
4. REMOVE FRONT DRIVE SHAFT
First pull the drive shaft inboard joint tulip from the side gear
shaft and then pull it out from the steering knuckle.
NOTICE:
Be careful not to damage the oil seal and boot.

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FA0810
FA0838
Matchmarks
SA1443Matchmarks
FA0841
SA−38
− SUSPENSION AND AXLEFRONT DRIVE SHAFT (4WD)
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see there is no play in the inboard and outboard
joints.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no obvious play in the radial
direction of the universal joints.
(d) Check the boot for damage.
2. REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
(a) Using a screwdriver, remove the 4 boot clamps.
(b) Slide the inboard joint boot toward the outboard joint.
3. DISASSEMBLE INBOARD JOINT TULIP
(a) Place matchmarks on the inboard joint tulip and drive
shaft.
(b) Remove the inboard joint tulip from the drive shaft.
4. DISASSEMBLE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
(b) Place matchmarks on the shaft and tripod.
(c) Using a brass bar and hammer, remove the tripod from
the drive shaft.
NOTICE:
Do not tap the roller.
5. REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS AND BOOTS
NOTICE:
Do not disassemble the outboard joint.
6. REMOVE DUST DEFLECTOR
Using a screwdriver and hammer, remove the dust deflector.

Downloaded from www.Manualslib.com manuals search engine SA0G0−02
FA0843
FA1795
Vinyl Tape
− SUSPENSION AND AXLEFRONT DRIVE SHAFT (4WD)
SA−39
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. INSTALL DUST DEFLECTOR
Using a screwdriver and hammer, install a new dust deflector.
2. TEMPORARILY INSTALL NEW INBOARD AND
OUTBOARD BOOTS AND NEW BOOT CLAMPS
HINT:
Before installing the boots, wrap vinyl tape around the spline of
the drive shaft to prevent the boots from being damaged.
3. INSTALL TRIPOD
(a) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks placed before disassembly.
(c) Using a brass bar and hammer, tap the tripod onto the
drive shaft.
NOTICE:
Do not tap the roller
(d) Using a snap ring expander, install a new snap ring.
4. ASSEMBLE BOOT TO OUTBOARD JOINT
Before assembling the boot, coat the outboard joint and boot
with grease in the boot kit.
Grease capacity:
176 − 186 g (6.21 − 6.56 oz.)
5. ASSEMBLE INBOARD JOINT TO INBOARD JOINT
TULIP
(a) Coat the inboard joint tulip and boot with grease in the
boot kit.
Grease capacity:
270 − 280 g (9.52 − 9.88 oz.)
(b) Align the matchmarks placed before disassembly.
(c) Install the inboard tulip to the drive shaft.
(d) Temporarily install the boot to the inboard tulip.

Downloaded from www.Manualslib.com manuals search engine FA0811
SA−40
− SUSPENSION AND AXLEFRONT DRIVE SHAFT (4WD)
1996 TOYOTA T100 (RM449U)
6. ASSEMBLE NEW BOOT CLAMPS TO BOTH BOOTS
(a) Make sure the 2 boots are on the shaft groove.
(b) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Standard length:
481.2 − 491.2 mm (18.945 − 19.339 in.)
(c) Using a screwdriver, bend the clamp and lock with a
screwdriver.
7. CHECK DRIVE SHAFT (See page SA−38)