TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine CH0I0−01
CH0784
Ohmmeter
Continuity
CH0783
Ohmmeter
No Continuity
CH0192
P13482
Ohmmeter
Continuity
P13565
Ohmmeter
No Continuity
− CHARGING (5VZ−FE)GENERATOR
CH−9
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
slip rings.
Standard resistance:
2.8 − 3.0 Ω at 20°C (68°F)
If there is no continuity, replace the rotor.
2. INSPECT ROTOR FOR GROUND
Using an ohmmeter, check that there is no continuity between
the slip ring and rotor.
If there is continuity, replace the rotor.
3. INSPECT SLIP RINGS
(a) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(b) Using vernier calipers, measure the slip ring diameters.
Standard diameter:
14.2 − 14.4 mm (0.559 − 0.567 in.)
Minimum diameter:
12.8 mm (0.504 in.)
4. INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
coil leads.
If there is no continuity, replace the drive end frame assembly.
5. INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between
the coil leads and drive end frame.
If there is continuity, replace the drive end frame assembly.

Downloaded from www.Manualslib.com manuals search engine P13534
Length
P13729
CH0414
10.5 mm
P13568
Terminal Positive (+)
Ohmmeter
Terminal Rectifer
P13566
Ohmmeter
Terminal Negative (−)
CH−10
− CHARGING (5VZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
6. INSPECT EXPOSED BRUSH LENGTH
Using vernier calipers, measure the exposed brush length.
Standard exposed length:
10.5 mm (0.413 in.)
Minimum exposed length:
1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the
brushes.
7. IF NECESSARY, REPLACE BRUSHES
(a) Unsolder and remove the brush and spring.
(b) Run the wire of the brush through the hole in the brush
holder, and insert the spring and brush into the brush
holder.
(c) Solder the brush wire to the brush holder at the exposed
length.
Exposed length:
10.5 mm (0.413 in.)
(d) Check that the brush moves smoothly in the brush holder.
(e) Cut off the excess wire.
(f) Apply insulation paint to the soldered point.
8. INSPECT POSITIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the posi-
tive (+) terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step
(a).
(c) Check that one shows continuity and the other shows no
continuity.
If continuity is not as specified, replace the rectifier holder.
9. INSPECT NEGATIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to each
negative (−) terminal and the other to each rectifier termi-
nal.
(b) Reverse the polarity of the tester probes and repeat step
(a).
(c) Check that one shows continuity and the other shows no
continuity.
If continuity is not as specified, replace the rectifier holder.

Downloaded from www.Manualslib.com manuals search engine CH0827
P22368
SST
P22369
SST
CH1026
− CHARGING (5VZ−FE)GENERATOR
CH−11
1996 TOYOTA T100 (RM449U)
10. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
11. IF NECESSARY, REPLACE FRONT BEARING
(a) Remove the 4 screws and bearing retainer.
(b) Using SST and a press, press out the bearing.
SST 09950−60010 (09951−00260, 09952−06010)
(c) Using SST and a press, press in a new bearing.
SST 09950−60010 (09951−00500)
(d) Install the bearing retainer with the 4 screws.
Torque:2.6 N·m (27 kgf·cm, 23 in.·lbf)
12. INSPECT REAR BEARING
Check that the bearing is not rough or worn.

Downloaded from www.Manualslib.com manuals search engine N00581
SST
P13567
N00578
SST
P00074
SST CH−12
− CHARGING (5VZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
13. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing cover and bearing.
SST 09820−00021
(b) Remove the bearing cover (inside).
(c) Place the bearing cover (inside) on the rotor.
(d) Using SST and a press, press in a new bearing.
SST 09820−00030
(e) Using SST, push in the bearing cover (outside).
SST 09285−76010

Downloaded from www.Manualslib.com manuals search engine CH02N−03
P13486
P13762
Upward
P13487
Wrench Socket
29 mm
P13597
SST (B)SST (A)
P10834
SST (B)
SST (C)Insert
− CHARGING (5VZ−FE)GENERATOR
CH−13
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation direction.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Install the 4 nuts.
Torque:4.5 N·m (46 kgf·cm, 39 in.·lbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63010
Torque:39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

Downloaded from www.Manualslib.com manuals search engine P04395
SST (A)
SST (C)
Turn
P13569
P13541
B07119
Upward
Protrusion
P13542
CH−14
− CHARGING (5VZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
(f) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque:110 N·m (1,125 kgf·cm, 81 ft·lbf)
(g) Remove the generator from SST (C).
(h) Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
(a) Install the 4 rubber insulators on the lead wires.
NOTICE:
Be careful of the rubber insulators installation direction.
(b) Install the rectifier with the 4 screws.
Torque: 2.0 N·m (20 kgf·cm, 18 in.·lbf)
6. INSTALL BRUSH HOLDER AND VOLTAGE
REGULATOR
(a) Install the brush holder cover to the brush holder.
NOTICE:
Be careful of the holder installation direction.
(b) Place the voltage regulator together with the brush holder
horizontally on the rectifier end frame.

Downloaded from www.Manualslib.com manuals search engine P13543
B05826
Push
P13397
P13571
− CHARGING (5VZ−FE)GENERATOR
CH−15
1996 TOYOTA T100 (RM449U)
(c) Install the 5 screws until there is a clearance of approx. 1
mm (0.04 in.) between the brush holder and voltage regu-
lator.
Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf)
(d) Fit the brush holder cover.
7. INSTALL REAR END COVER
(a) Install the end cover with the 3 nuts.
Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf)
(b) Install the terminal insulator with the nut.
Torque:4.1 N·m (42 kgf·cm, 36 in.·lbf)
8. CHECK THAT ROTOR ROTATES SMOOTHLY

Downloaded from www.Manualslib.com manuals search engine CH02O−02
CH−16
− CHARGING (5VZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page CH−6).

Downloaded from www.Manualslib.com manuals search engine CL – CLUTCH

TROUBLESHOOTING CL-1
CLUTCH PEDAL CL-2
CLUTCH MASTER CYLINDER CL-5
CLUTCH RELEASE CYLINDER CL-10
CLUTCH UNIT CL-15

Downloaded from www.Manualslib.com manuals search engine CL026−01
− CLUTCHTROUBLESHOOTING
CL−1
1236 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
3. Clutch disc (Oily)
4. Clutch disc (Worn out)
5. Clutch disc (Damaged torsion rubber)
6. Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment)−
CL−15
CL−15
CL−15
CL−15
CL−15
CL−19
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged)−
CL−5
CL−10
Clutch noisy
1. Release bearing (Worn, dirty or damaged)
2. Input shaft bearing (Worn, dirty or damaged)
3. Clutch disc torsion rubber (Damaged)CL−15
−
CL−15
Clutch slips
1. Clutch pedal (Freeplay out of adjustment)
2. Clutch disc (Oily)
3. Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel (Distortion)CL−2
CL−15
CL−15
CL−15
CL−15
−
Clutch does not disengage
1. Clutch pedal (Freeplay out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder cup (Damaged)
4. Release cylinder cup (Damaged)
5. Input shaft bearing (Worn, dirty or damaged)
6. Clutch disc (Out of true)
7. Clutch disc (Runout is excessive)
8. Clutch disc (Lining broken)
9. Clutch disc (Dirty or burred)
10. Clutch disc (Oily)
11. Clutch disc (Lack of spline grease)
12. Diaphragm spring (Damaged)
13. Diaphragm spring (Out of tip alignment)
14. Pressure plate (Distortion)CL−2
−
CL−5
CL−10
−
CL−15
CL−15
CL−15
CL−15
CL−15
CL−19
CL−15
CL−19
CL−15