TOYOTA T100 1996 Factory Service Manual

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Cover
Pad
Plate
Lever MT:
For 2WDSteering Column AssemblySteering Wheel Steering Wheel
Steering Wheel Lower
No.3 Cover
Torx Screw
Combination Switch
(w/ Spiral Cable)
Column Lower Cover
Light Control Rheostat
Front Door Scuff x7
Sliding w/ Shaft York
Sub−Assembly
Lower Finish Panel No.1 Column Hole CoverColumn Upper
Torx Screw
Steering Wheel Lower
No.2 Cover
Intermediate
Engine Hood Release Shaft Assembly
Duct Heater to
Register No.2
Intermediate
Shaft Assembly
Cowl Side Trim 9.0 (90, 78 in.·lbf)
35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
25 (260, 19)
9.0 (90, 78 in.·lbf)
35 (360, 26)
35 (360, 26)
35 (360, 26)
SR−24
− STEERINGTILT STEERING COLUMN
1698 Author: Date:
1996 TOYOTA T100 (RM449U)

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Tilt Pawl Stopper
Tilt Lever
Tilt Lever Lock Shaft
Tension Spring
Compression Spring
Bearing Thrust Collar
 BearingWasher
Tilt Pawl
Column Upper Tube
 Snap Ring
Tum Signal Bracket
Tilt Lever
Assembly
Tilt Sub Lever
Tilt Pawl Stopper
Main Shaft Assembly
Stopper
Collar
A/T:
Key Cylinder
Key Unlock
Warning
Switch
Tilt Lever Ratainer
Column Upper
Bracket Ignition
Switch
 E−ringBolt Tilt No.2
Bushing Tension Spring
Key Unlock Warning Switch
Ignition Switch
Column Upper
Bracket
Column LowerTilt Lever
Ratainer
 E−ring
Tension
Speing
Tilt No.2 Bolt Tube
 Bushing
Sliding York Sub−Assembly
Non−reusable part
Molybdenum disulfide lithium base grease Snap Ring
 tapered−Head Bolt
Column Upper Clamp Key Cylinder
Tilt Pawl
35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
7.8 (80, 69 in.·lbf)
5.9 (60, 52 in.·lbf)
7.8 (80, 69 in.·lbf)
15 (150, 11)
2.0 (20, 17 in.·lbf)
− STEERINGTILT STEERING COLUMN
SR−25
1699 Author: Date:
1996 TOYOTA T100 (RM449U)

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SR−26
− STEERINGTILT STEERING COLUMN
1996 TOYOTA T100 (RM449U)
REMOVAL
(See page SR−13)

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R15245
Matchmarks
R11947
Screw Extractor
R15212
SSTBolt
SST Nut Tilt No.2 Bolt
Plate Washer
− STEERINGTILT STEERING COLUMN
SR−27
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE SLIDING YOKE SUB−ASSEMBLY
(a) Remove the bolt.
(b) Shift the yoke.
(c) Place matchmarks on the sliding yoke and main shaft.
2. REMOVE COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Using a centering punch, mark the center of the 2 ta-
pered−head bolts.
(b) Using a 3 − 4 mm (0.12 − 0.16 in.) drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts.
3. REMOVE 3 TENSION SPRINGS
4. REMOVE COMPRESSION SPRING
(a) Remove the bolt with the spring.
(b) Remove the 2 bushings from the spring.
5. REMOVE 2 TILT LEVER RETAINERS
(a) Remove the E−ring from the tilt lever lock shaft.
(b) Remove the nut and retainer.
6. REMOVE 2 TILT PAWL STOPPERS
7. REMOVE 2 TILT PAWLS
(a) Remove the tilt lever assembly set bolt.
(b) Remove the nut and bolt.
(c) Remove the washer.
8. REMOVE TILT LEVER ASSEMBLY, TILT SUB LEVER,
TILT LEVER AND TILT LEVER LOCK SHAFT
9. REMOVE COLUMN UPPER TUBE WITH MAIN SHAFT
ASSEMBLY
(a) Set SST, the nut (10 mm nominal diameter, 1.25 mm
pitch), plate washer (36 mm outer diameter) and bolt (10
mm nominal diameter, 1.25 mm pitch, 50 mm length), as
shown in the illustration.
SST 09910−00015 (09911−00011, 09912−00010)
Reference
Nut: 90170−10004
Plate washer: 90201−10201
Bolt: 91111−51050
(b) Remove the 2 tilt No.2 bolts by using the sliding hammer
on SST.
(c) Remove the upper tube with the shaft assembly from the
lower tube.
(d) Remove the collar and stopper from the shaft assembly.
10. REMOVE TURN SIGNAL BRACKET
Remove the 2 bolts.

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SSTSST SR−28
− STEERINGTILT STEERING COLUMN
1996 TOYOTA T100 (RM449U)
11. REMOVE MAIN SHAFT ASSEMBLY
(a) Using SST, compress the compression spring.
SST 09950−40010 (09957−04010, 09958−04010)
NOTICE:
Do not bend the universal joint of the main shaft more than
20°.
(b) Using a snap ring expander, remove the snap ring from
the shaft assembly.
(c) Remove the main shaft from the column upper tube.
(d) Remove the compression spring, bearing thrust collar
and bearing from the shaft assembly.

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− STEERINGTILT STEERING COLUMN
SR−29
1996 TOYOTA T100 (RM449U)
INSPECTION
(See page SR−17)

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R11780
SST
SST
R13024
1
2Hollow Tipped
Mark Position
R04528
R04529
SR−30
− STEERINGTILT STEERING COLUMN
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM
BASE GREASE
(See pages SR−23)
2. INSTALL MAIN SHAFT ASSEMBLY
(a) Install the bearing, bearing thrust collar and compression
spring to the main shaft.
(b) Install the main shaft into the column upper tube.
(c) Using SST, compress the compression spring.
SST 09950−40010 (09957−04010, 09958−04010)
NOTICE:
Do not bend the universal joint of the main shaft more than
20°.
(d) Using a snap ring expander, install a new snap ring.
3. INSTALL TURN SIGNAL BRACKET
Torque the 2 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)
4. SELECT 2 TILT NO.2 BOLTS
Select the bolt with the hollow−tipped thread end when the col-
umn upper tube mark is 1, and the bolt with the plain thread end
when the mark is 2.
NOTICE:
Select the bolt type to match each number marked in the
squares on the upper tube.
5. INSTALL COLUMN UPPER TUBE WITH MAIN SHAFT
ASSEMBLY
(a) Install the stopper and collar to the shaft assembly.
(b) Install the upper tube with the shaft assembly to the col-
umn lower tube.
(c) Using a plastic hammer, drive in the 2 tilt No.2 bolts.
6. INSTALL TILT LEVER LOCK SHAFT, TILT LEVER
ASSEMBLY AND TILT SUB LEVER, TILT LEVER
Torque the tilt lever assembly set bolt.
Torque: 2 N·m (20 kgf·cm, 17 in.·lbf)

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R15213
Tilt Pawl
Alignment Mark
Tilt Pawl Stopper
SR3128
”A” ”A”
Mark
− STEERINGTILT STEERING COLUMN
SR−31
1996 TOYOTA T100 (RM449U)
7. INSTALL 2 TILT PAWLS
Install the pawl to the column upper tube and temporarily install
the washer with the bolt and nut.
HINT:
Install the pawl pin into the long hole of the tilt lever/tilt sub lever.
8. ENGAGE AND ADJUST 2 TILT PAWLS
(a) Engage the tilt sub lever side pawl to the center of the
ratchet.
(b) While turning the tilt lever side collar, engage the tilt lever
side pawl to the ratchet completely.
(c) Torque the nut.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(d) Check that the pawls rotate smoothly.
9. SELECT 2 TILT PAWL STOPPERS
(a) With the tilt pawl and ratchet engaged, install the 2 pawl
stoppers.
(b) Check that the alignment marks on the stopper and pawl
align when the stopper is lightly rotated to the pawl side.
(c) If the alignment marks are not align, select pawl stopper
according to the following table.
Right pawl stopperLeft pawl stopperDimension ”A”
mm (in.)
1A12.68 − 12.74
(0.4992 − 0.5016)
2B12.61 − 12.67
(0.4965 − 0.4988)
3C12.54 − 12.60
(0.4937 − 0.4961)
4D12.47 − 12.53
(0.4909 − 0.4933)
5E12.40 − 12.46
(0.4882 − 0.4906)
6F12.33 − 12.39
(0.4854 − 0.4878)
7G12.26 − 12.32
(0.4827 − 0.4850)
(d) After selecting the stoppers, check that the pawl and
ratchet are fully engaged.
10. INSTALL 2 TILT PAWL STOPPERS
11. INSTALL 2 TILT LEVER RETAINERS
(a) Install the tilt lever retainer and torque the nut.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(b) Install a new E−ring.
12. INSTALL COMPRESSION SPRING
(a) Install the 2 bushings to the compression spring.
(b) Install the spring with the bolt.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

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SR−32
− STEERINGTILT STEERING COLUMN
1996 TOYOTA T100 (RM449U)
13. INSTALL 3 TENSION SPRINGS
14. INSTALL COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Install the bracket with 2 new tapered−head bolts.
(b) Tighten the tapered−head bolts until the bolt heads break
off.
15. INSTALL SLIDING YORK SUB−ASSEMBLY
(a) Align the matchmarks on the sliding york and main shaft.
(b) Torque the bolt.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
16. CHECK TILT STEERING OPERATION
(a) Check that there is no axial play at the end of the main
shaft.
(b) With the main shaft in the neutral position, pull the tilt lever
and check that the main shaft rises to the uppermost posi-
tion.
(c) Lower the main shaft, and check that it locks in the lower-
most position.

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− STEERINGTILT STEERING COLUMN
SR−33
1996 TOYOTA T100 (RM449U)
INSTALLATION
(See page SR−20)