relay TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SA0384
Air FilterE
F
SA0385
Air FilterE
F
SA0375
1
2 3
4
61
23
4
6
Z04174
Z04175
− SUSPENSION AND AXLEA.D.D. CONTROL SYSTEM
SA−71
1996 TOYOTA T100 (RM449U)
(b) Connect the battery to the solenoid.
Check that air flows from the port E to port F.
Check that air does not flow from the port E to the air filter.
(c) Disconnect the battery positive voltage from the solenoid.
Check that air flows from the port E to the air filter.
Check that air does not flow from the port E to port F.
5. INSPECT A.D.D. RELAY
(a) Using an ohmmeter, check that continuity exists between
terminals 1 and 3.
(b) Using an ohmmeter, check that continuity exists between
terminals 2 and 6.
(c) Connect the positive (+) lead from the battery to terminal
6 and the negative (−) lead to terminal 2.
(d) Using an ohmmeter, check that continuity exists between
terminals 1 and 4.
6. INSPECT A.D.D. INDICATOR SWITCH
(a) Using an ohmmeter, check that continuity exists between
terminals when the switch when the switch is pushed (dif-
ferential connected position).
(b) Using an ohmmeter, check that continuity doesn’t exists
when the switch is free (differential disconnected posi-
tion).
7. INSPECT TRANSFER INDICATOR SWITCH
(a) Using an ohmmeter, check that there is continuity be-
tween terminals between terminals when the switch is
pushed (transfer 4WD position).
(b) Using an ohmmeter, check that there is continuity be-
tween terminals when switch is free (transfer H2 position).

Downloaded from www.Manualslib.com manuals search engine F14857
BR1NW−01
R07778
BR−58
− BRAKEABS ACTUATOR
1663 Author: Date:
1996 TOYOTA T100 (RM449U)
ABS ACTUATOR
ON−VEHICLE INSPECTION
1. INSPECT BATTERY POSITIVE VOLTAGE
Battery positive voltage: 10 − 14 V
2. DISCONNECT CONNECTORS
(a) Disconnect the 2 connectors from the control relay.
(b) Disconnect the connector from the actuator.
3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA-
TOR
(a) Connect the actuator checker (SST) to the actuator, con-
trol relay and body side wire harness through the sub−
wire harness C and E (SST) as shown in the illustration.
SST 09990−00150, 09990−00200, 09990−00210
(b) Connect the red cable of the checker to the battery posi-
tive (+) terminal and black cable to the negative (−) termi-
nal. Connect the black cable of the sub−wire harnesses
to the battery negative (−) terminal or body ground.
(c) Place the ”SHEET L” (SST) on the actuator checker.
SST 09990−00370
4. INSPECT BRAKE ACTUATOR OPERATION
(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker in
”FRONT” position.
(c) Push and hold in the MOTOR switch for a few seconds.
Make sure that you can hear the motor running.

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R07784
R07785
R07782
BR−60
− BRAKEABS ACTUATOR
1665 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Push the REAR switch while pressing the POWER
SWITCH, and check that the brake pedal cannot be de-
pressed.
NOTICE:
Do not keep the POWER SWITCH pushed down for more
than 10 seconds.
(e) Release the REAR switch then the POWER SWITCH,
and check that the brake pedal can be depressed.
(f) Push and hold in the MOTOR switch for a few seconds,
and check that the pedal returns.
(g) Release the brake pedal.
(h) Push and hold in the MOTOR switch for a few seconds.
(i) Depress the brake pedal and hold it for about 15 seconds.
As you hold the pedal down, push the MOTOR switch for
a few seconds. Check that the brake pedal does not pul-
sate.
(j) Release the brake pedal.
7. PUSH MOTOR SWITCH
(a) Push and hold on the MOTOR switch for a few seconds.
(b) Stop the engine.
8. DISCONNECT ACTUATOR CHECKER (SST) FROM
ACTUATOR
Remove the ”SHEET L” (SST) and disconnect the actuator
checker (SST) and sub−wire harness (SST) from the actuator,
control relay and body side wire harness.
SST 09990−00150, 09990−00200, 09990−00210,
09990−00370
9. CONNECT CONNECTOR TO ACTUATOR
10. CLEAR DTC (See page DI−321)

Downloaded from www.Manualslib.com manuals search engine R15457
Return Tube
Intermediate Shaft Assembly
Pressure Feed Tube
PS Gear Assembly
Pitman Arm Sub−Assembly
With Relay Rod
Spring Washer 44 (450, 33)
*36 (365, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
35 (360, 26)
44 (450, 33)
*36 (365, 26)
142 (1450, 105)
177 (1800, 130)
SR080−01
SR−72
− STEERINGPOWER STEERING GEAR (4WD)
1746 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING GEAR (4WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine SR081−01
R08049
SST
R12957
SST SR−74
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD
(See page SR−13)
3. REMOVE STEERING WHEEL
(See page SR−13)
4. DISCONNECT PITMAN ARM SUB−ASSEMBLY WITH
RELAY ROD
(a) Remove the pitman arm set nut and spring washer.
(b) Using SST, disconnect the pitman arm from the gear as-
sembly.
SST 09628−62011
5. DISCONNECT PRESSURE FEED TUBE AND RETURN
TUBE
Using SST, disconnect the tube.
SST 09631−22020
6. DISCONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−13)
7. REMOVE PS GEAR ASSEMBLY
Remove the 3 bolts, nuts and washers.

Downloaded from www.Manualslib.com manuals search engine SR085−01
R15509
Fulcrum
Length
SST
SR2922
Alignment Marks
− STEERINGPOWER STEERING GEAR (4WD)
SR−83
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Install the 3 bolts, washers and nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
2. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
3. CONNECT PRESSURE FEED TUBE AND RETURN
TUBE
Using SST, connect the tube.
SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT PITMAN ARM SUB−ASSEMBLY WITH
RELAY ROD
(a) Align the alignment marks on the pitman arm and sector
shaft, and connect the pitman arm.
(b) Install the spring washer and pitman arm set nut.
Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
5. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
6. CENTER SPIRAL CABLE
(See page SR−20)
7. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering column
main shaft.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
8. BLEED POWER STEERING SYSTEM
(See page SR−4)
9. CHECK STEERING WHEEL CENTER POINT
10. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
11. INSTALL STEERING WHEEL PAD
(See page SR−20)
12. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)

Downloaded from www.Manualslib.com manuals search engine R15252
RH Tie Rod End
Sub−Assembly
RH Knuckle Arm
Steering Damper
 Non−reusable partEngine Under CoverSpring WasherPitman ArmLH Knuckle Arm LH Tie Rod Sub−Assembly
LH Tie Rod End Assembly RH Tie Rod
Idler Arm
Assembly
Relay Rod
 Cotter PinLH Tie Rod
Assembly Clamp
Tie Rod
Clamp
Clamp
Tie Rod
Clamp
Sub−Assembly
Sub−Assembly RH Tie Rod
 
 22 (225, 16)
22 (225, 16)
22 (225, 16)
22 (225, 16)
90 (920, 67)
177 (1800, 130)
90 (920, 67)
25 (260, 19)
59 (600, 43)
90 (920, 67)
90 (920, 67)
142 (1450, 105)
: Specified torque
N·m (kgf·cm, ft·lbf)
59 (600, 43)
SR086−01
SR−84
− STEERINGSTEERING LINKAGE
1758 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING LINKAGE
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine SR087−01
R08049
SST
R15244
SST
R04470
SST
SR1254
SST
SR1260
SST
− STEERINGSTEERING LINKAGE
SR−85
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE ENGINE UNDER COVER
Remove the 4 bolts.
2. REMOVE PITMAN ARM
(a) Remove the pitman arm set nut and spring washer.
(b) Using SST, disconnect the pitman arm from the cross
shaft.
SST 09628−62011
(c) Remove the cotter pin and nut.
(d) Using SST, disconnect the pitman arm from the relay rod.
SST 09611−22012
3. REMOVE LH AND RH TIE ROD ASSEMBLIE
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod assembly from the relay
rod.
SST 09628−62011
(c) Remove the cotter pin and nut.
(d) Using SST, disconnect the tie rod assembly from the
knuckle arm.
SST 09610−20012
4. REMOVE RH AND LH TIE ROD SUB−ASSEMBLIES,
TIE ROD END SUB−ASSEMBLIES, TIE RODS AND 2
CLAMPS
Remove the 2 bolts, washers and nuts.
5. REMOVE STEERING DAMPER
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the steering damper from the relay
rod.
SST 09611−22012
(c) Remove the bolt and nut.

Downloaded from www.Manualslib.com manuals search engine R08099
SST SR−86
− STEERINGSTEERING LINKAGE
1996 TOYOTA T100 (RM449U)
6. REMOVE IDLER ARM ASSEMBLY
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the idler arm from the relay rod.
SST 09610−20012
(c) Remove the 3 bolts, washers and nuts.

Downloaded from www.Manualslib.com manuals search engine SR088−02
R08100
AA = A’
B = B’ BB’ A’
Z03912
Front
Front
SR0262 SR1454
− STEERINGSTEERING LINKAGE
SR−87
1996 TOYOTA T100 (RM449U)
INSTALLATION
HINT:
When connecting the ball stud to the arm or rod, remove the
grease on the joint surfaces.
1. INSTALL IDLER ARM ASSEMBLY
(a) Install the 3 bolts, washers and nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
(b) Connect the idler arm to the relay rod.
(c) Install the nut and a new cotter pin.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
2. INSTALL STEERING DAMPER
(a) Torque the bolt and nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(b) Install the nut and a new cotter pin.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
3. INSTALL RH AND LH TIE ROD SUB−ASSEMBLIES,
TIE ROD END SUB−ASSEMBLIES, TIE ROD AND 2
CLAMPS
(a) Screw the tie rod end sub−assembly and tie rod sub−as-
sembly into the tie rod.
HINT:
The tie rod assembly length should be approximately 329.2 mm
(12.961 in.), and the remaining length of threads on both RH
and LH tie rod assemblies should be equal.
(b) Turn the tie rod end sub−assembly so that they cross at
about 90 degrees.
(c) After adjusting toe−in, torque the bolt.
(See page SA−10)
Torque: 22 N·m (225 kgf·cm, 16 ft·lbf)
4. INSTALL RH AND LH TIE ROD ASSEMBLIES
(a) Connect the tie rod assembly to the knuckle arm.
(b) Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
(c) Connect the tie rod assembly to the relay rod.
(d) Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)