TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine R02495
Proper ContactToe Contact Flank Contact Heel Contact Face Contact
Select an adjusting shim that will bring the drive
pinion closer to the ring gear.
Select an adjusting shim that will shift the drive
pinion away from the gear.
R04554
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−151
1996 TOYOTA T100 (RM449U)
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.
Washer thickness
Thickness
Mark mm (in.)Thickness
Mark mm (in.)Thickness
Mark mm (in.)
87 1.87 (0.0736) 01 2.01 (0.0791) 15 2.15 (0.0846)
88 1.88 (0.0740) 02 2.02 (0.0795) 16 2.16 (0.0850)
89 1.89 (0.0744) 03 2.03 (0.0799) 17 2.17 (0.0854)
90 1.90 (0.0748) 04 2.04 (0.0803) 18 2.18 (0.0858)
91 1.91 (0.0752) 05 2.05 (0.0807) 19 2.19 (0.0862)
92 1.92 (0.0756) 06 2.06 (0.0811) 20 2.20 (0.0866)
93 1.93 (0.0760) 07 2.07 (0.0815) 21 2.21 (0.0870)
94 1.94 (0.0764) 08 2.08 (0.0819) 22 2.22 (0.0874)
95 1.95 (0.0768) 09 2.09 (0.0823) 23 2.23 (0.0878)
96 1.96 (0.0772) 10 2.10 (0.0827) 24 2.24 (0.0882)
97 1.97 (0.0776) 11 2.11 (0.0831) 25 2.25 (0.0886)
98 1.98 (0.0780) 12 2.12 (0.0835) 26 2.26 (0.0890)
99 1.99 (0.0783) 13 2.13 (0.0839) 27 2.27 (0.0894)
00 2.00 (0.0787) 14 2.14 (0.0843) 28 2.28 (0.0898)

Downloaded from www.Manualslib.com manuals search engine R11163SST
R04341
SST
SA2351
SST
SA2352
SA−152
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
14. REMOVE COMPANION FLANGE (See page SA−140)
15. REMOVE FRONT BEARING (See page SA−140)
16. INSTALL NEW BEARING SPACER, WASHERS AND
FRONT BEARING
(a) Install a new bearing spacer and 2 washers, and place the
front bearing.
(b) Using SST and the companion flange, install the front
bearing then remove the companion flange.
SST 09950−30010
17. INSTALL NEW OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST and a press, tap in the oil seal until its surface
with the differential carrier end.
SST 09316−12010, 09649−17010,
HINT:
Connect SST with vinyl tape.
18. INSTALL COMPANION FLANGE
(a) Install the companion flange on the shaft.
(b) Coat the threads of a new nut with hypoid gear oil.
(c) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 147 N·m (1,500 kgf·cm, 109 ft·lbf)
19. ADJUST DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash
between the drive pinion and ring gear.
Preload (at starting):
New bearing:
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing:
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
If preload is greater than the specification, replace the bearing
spacer.
If preload is less than specification, retorque the nut a little at
a time with a torque of 13 N·m (130 kgf·cm, 9 ft·lbf) until the spe-
cified preload is reached.

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SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−153
1996 TOYOTA T100 (RM449U)
Torque: 451 N·m (4,600 kgf·cm, 333 ft·lbf) or less
If the maximum torque is exceeded with retightening the nut, re-
place the bearing spacer and repeat the preload adjusting pro-
cedure. Do not loosen the pinion nut to reduce the preload.
20. INSTALL DIFFERENTIAL CASE IN CARRIER (See
page SA−145)
21. RECHECK TOTAL PRELOAD (See page SA−145)
22. RECHECK RING GEAR BACKLASH (See page
SA−145)
23. RECHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−145)
24. CHECK RUNOUT OF COMPANION FLANGE (See
page SA−140)
25. STAKE DRIVE PINION NUT

Downloaded from www.Manualslib.com manuals search engine SA0I7−02
RA10720 − 5 mm (0 − 0.20 in.) OilFiller Hole SA−154
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL NEW GASKET TO AXLE HOUSING
2. INSTALL DIFFERENTIAL CARRIER ASSEMBLY
Install the differential carrier assembly in the axle housing.
Torque: 73 N·m (740 kgf·cm, 54 ft·lbf)
3. INSTALL PROPELLER SHAFT
2WD: See page PR−9
4WD: See page PR−16
4. INSTALL REAR AXLE SHAFTS
(See page SA−135)
5. FILL DIFFERENTIAL WITH DIFFERENTIAL OIL
Torque:
Drain plug: 49 N·m (500 kgf·cm, 39 ft·lbf)
Filler plug: 39 N·m (400 kgf·cm, 29 ft·lbf)
Oil type: Hypoid gear oil API GL−5
Recommended oil viscosity:
Above −18°C (0°F) SAE 90
Below −18°C (0°F) SAE 80W or 80W − 90
Capacity: 2.35 liters (2.22 US qts, 2.67 lmp.qts)

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W00408
RetainerBushing
Retainer
Rear Shock Absorber
Retainer
Bushing
Retainer
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
SA−155
1594 Author: Date:
1996 TOYOTA T100 (RM449U)
REAR SHOCK ABSORBER
COMPONENTS

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SA−156
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
1996 TOYOTA T100 (RM449U)
REMOVAL
1. SUPPORT BODY WITH STANDS
(a) Jack up and support the body on stands.
(b) Lower the axle housing until the leaf spring tension is free and keep it at this position.
2. REMOVE REAR SHOCK ABSORBER
(a) Remove the 2 rear shock absorber set bolts.
Torque: 26 N·m (260 kgf·cm, 19 ft·lbf)
(b) Remove the rear shock absorber.

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RA0851
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
SA−157
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual operation sounds.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When discarding the shock absorber, use the following
procedure.

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RA0807
10 − 20 mm (0.39 − 0.79 in.) SA−158
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
1996 TOYOTA T100 (RM449U)
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder, as shown to remove
the gas inside.

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− SUSPENSION AND AXLEREAR SHOCK ABSORBER
SA−159
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−156).

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SA−160
− SUSPENSION AND AXLEREAR LEAF SPRING
1599 Author: Date:
1996 TOYOTA T100 (RM449U)
REAR LEAF SPRING
COMPONENTS