TOYOTA T100 1996 Factory Service Manual

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R04398
Matchmarks
F14974
Z04243
Matchmarks
SST
S
Q06614
SST
F14975
PR−4
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (2WD)
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
a vise as this will cause deformation.
1. TMC−made:
SEPARATE PROPELLER SHAFT AND INTERMEDI-
ATE SHAFT
(a) Place matchmarks on the flanges.
(b) Remove the 4 bolts, washers and nuts.
2. DANA−made:
SEPARATE PROPELLER SHAFT AND INTERMEDI-
ATE SHAFT
(a) Place matchmarks on the yoke and propeller shaft.
(b) Disassemble center yoke.
(See SPIDER BEARING REPLACEMENT on page
PR−18)
3. TMC−made:
REMOVE CENTER SUPPORT BEARING FROM IN-
TERMEDIATE SHAFT
(a) Using a hammer and chisel, loosen the staked part of the
nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
(c) Place matchmarks on the flange and shaft.
(d) Using SST, remove the flange from the intermediate
shaft.
SST 09950−30010
(e) Remove the center support bearing from the intermediate
shaft.
4. DANA−made:
REMOVE CENTER SUPPORT BEARING FROM IN-
TERMEDIATE SHAFT
(a) Using a hammer and chisel, loosen the staked part of the
nut.
(b) Clamp the yoke in a vise and remove the nut.
(c) Place matchmarks on the yoke and shaft.
(d) Clamp the yoke in a vise and top off the shaft.
(e) Using a brass bar and hammer, remove the center sup-
port bearing from the intermediate shaft.

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R04446
R04447
R04478
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (2WD)
PR−5
1996 TOYOTA T100 (RM449U)
INSPECTION
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
a vise as this will cause deformation.
1. INSPECT PROPELLER SHAFT AND INTERMEDIATE
SHAFT FOR DAMAGE OR RUNOUT
Using a dial indicator, check each runout of shaft.
Maximum runout: 0.8 mm (0.031 in.)
If shaft runout is greater than the maximum, replace the shaft.
2. INSPECT SPIDER BEARING
(a) Inspect the spider bearing for wear or damage.
(b) Using a dial indicator, check the spider bearing axial play
by turning the yoke of flange while holding the shaft tight-
ly.
Bearing axial play: 0.05 mm (0.0020 in.)
3. INSPECT CENTER SUPPORT BEARING FOR WEAR
OR DAMAGE
Check that the bearing turns freely.
If the bearing is damaged, worn, or does not turn freely, replace
it.

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TMC
DANA
PR01K−02
R04431
Front
F14976
PR−6
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (2WD)
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
When removing or installing any part, make sure that each joint
is facing the correct direction, as shown in the illustration below.
1. TMC−made:
INSTALL CENTER SUPPORT BEARING ON INTER-
MEDIATE SHAFT
HINT:
Install the center support bearing in the direction, as shown.
2. INSTALL FLANGE ON INTERMEDIATE SHAFT
(a) Coat the splines of the intermediate shaft with MP grease.
(b) Place the flange on the shaft and align the marks.
HINT:
If replacing either the center flange or intermediate shaft, reas-
semble them so that the front yoke of the intermediate shaft and
the rear yoke of the propeller shaft are facing in the same direc-
tion.

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SST
R04398
Matchmarks
R04431
Front
F
F14975
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (2WD)
PR−7
1996 TOYOTA T100 (RM449U)
(c) Using SST to hold the flange, press the bearing into posi-
tion by tightening down a new nut.
SST 09330−00021
Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
(d) Loosen the nut.
(e) Torque the nut again.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(f) Using a hammer and chisel, stake the nut.
3. INSTALL PROPELLER SHAFT
(a) Align the matchmarks on the flange and connect the
flanges with 4 bolts, washers and nuts.
HINT:
If replacing either the center flange or intermediate shaft, reas-
semble them so that the front yoke of the intermediate shaft and
the rear yoke of the propeller shaft are facing in the same direc-
tion.
(b) Torque the bolts.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
4. DANA−made:
INSTALL CENTER SUPPORT BEARING INTERMEDI-
ATE SHAFT
HINT:
Install the center support bearing in the direction, as shown.
5. INSTALL YOKE ON INTERMEDIATE SHAFT
(a) Coat the splines of the intermediate shaft with MP grease.
(b) Place the center yoke on the shaft and align the match-
marks.
HINT:
If replacing either the center yoke or intermediate shaft.
(c) Clamp the yoke in a vise, press the bearing into position
by tightening down a new nut.
Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
(d) Loosen the nut.
(e) Torque the nut again.
Torque: 81 N·m (830 kgf·cm, 60 ft·lbf)
(f) Using a hammer and punch, stake the nut.

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PR−8
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (2WD)
1996 TOYOTA T100 (RM449U)
6. CONNECT PROPELLER SHAFT AND INTERMEDIATE
SHAFT
Assemble the center yoke (See SPIDER BEARING REPLACE-
MENT on page PR−18).

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R15507Matchmarks
R04434
TMC
90Bracket Center
Line
Shaft Axial
Direction
R04435
DANA
90Bracket Center
Line
Shaft Axial
Direction
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (2WD)
PR−9
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PROPELLER SHAFT
(a) Remove SST from the transmission.
SST 09325−40010
(b) Insert the yoke into the transmission.
(c) Temporarily install the center support bearing with 2
mounting bolts.
HINT:
Make sure the bearing is installed with facing the drain hole
downwards.
(d) Align the matchmarks on the flanges and connect the
flanges with the 4 bolts, washers and nuts.
(e) Torque the 4 bolts.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
2. ADJUST CENTER SUPPORT BEARING
HINT:
With the vehicle unladen, adjust the center support bear-
ing to keep the intervals, as shown.
At the same condition, check the center line in the axial
direction. Adjust the bearing if necessary.
Check that the center line of the center bearing is set to
the center line of the bracket when the vehicle is unladen.
Adjust the bracket if necessary.
Torque the 2 bolts.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)

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F14977
PR−10
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (4WD)
1428 Author: Date:
1996 TOYOTA T100 (RM449U)
PROPELLER SHAFT ASSEMBLY (4WD)
COMPONENTS

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R04437
Matchmarks
R04440
Matchmarks
R04441
Matchmarks
R15508Matchmarks
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (4WD)
PR−11
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT PROPELLER SHAFT
(a) Place matchmarks on the differential and propeller shaft
flange.
(b) Remove the 4 bolts, washers and nuts, disconnect the
propeller shaft from the differential.
(c) M/T:
Remove the 2 bolts, nuts and propeller shaft No.2 dust
cover.
(d) Remove the 3 bolts and propeller shaft dust cover.
(e) Suspend the front side of the propeller shaft.
(f) Place matchmarks on the transfer and propeller shaft
flanges.
(g) Remove the 4 nuts and washers.
(h) Remove the propeller shaft from the transfer.
2. REMOVE REAR PROPELLER SHAFT
(a) Place matchmarks on the differential and propeller shaft
flanges.
(b) Remove the 4 bolts, washers and nuts, disconnect the
propeller shaft from the differential.
(c) Remove the 4 bolts and protector.
(d) Remove the 2 mounting bolts and center support bearing.
(e) Place matchmarks on the transfer and propeller shaft
flanges.
(f) Remove the 4 nuts and washers, and the propeller shaft.

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R04444
Matchmarks
R04445
Matchmarks
Z04243
Matchmarks
SST
Q06613
SST PR−12
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (4WD)
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. Front:
REMOVE SLEEVE YOKE FROM FRONT PROPELLER
SHAFT
(a) Place matchmarks on the sleeve yoke and propeller
shaft.
(b) Pull out the sleeve yoke from the propeller shaft.
2. Rear:
SEPARATE PROPELLER SHAFT AND INTERMEDI-
ATE SHAFT
(a) Place the matchmarks on the flanges.
(b) Remove the 4 nuts, bolts and washers.
3. REMOVE CENTER SUPPORT BEARING FROM IN-
TERMEDIATE SHAFT
(a) Using a hammer and chisel, loosen the staked part of the
nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
(c) Place matchmarks on the flange and shaft.
(d) Using SST, remove the flange from the intermediate
shaft.
SST 09950−30010
(e) Remove the center support bearing from the intermediate
shaft.

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R04446
R04447
R04478
R04479
Double Cardan
Joint
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (4WD)
PR−13
1996 TOYOTA T100 (RM449U)
INSPECTION
NOTICE:
Be careful not to grip the propeller shaft tube too tightly in
a vise as this will cause deformation.
1. INSPECT PROPELLER SHAFT AND INTERMEDIATE
SHAFT FOR DAMAGE OR RUNOUT
Using a dial indicator, check the runout of shafts.
Maximum runout: 0.8 mm (0.031 in.)
If shaft runout is greater than the maximum, replace the shaft.
2. INSPECT SPIDER BEARING
(a) Inspect the spider bearing for wear or damage.
(b) Using a dial indicator, check the spider bearing axial play
by turning the yoke of flange while holding the shaft tight-
ly.
Bearing axial play: 0.05 mm (0.0020 in.)
3. INSPECT CENTER SUPPORT BEARING FOR WEAR
OR DAMAGE
Check that the bearing turns freely.
If the bearing is damaged, worn, or does not turn freely, replace
it.
HINT:
When replacing the rear propeller shaft spider, be sure that the
grease fitting assembly hole is facing in the direction shown in
the illustration.
4. INSPECT WITH DOUBLE CARDAN JOINT PROPEL-
LER SHAFT
(a) Inspect the shaft for wear or damage.
(b) Inspect the double cardan joint for wear damage.
If any problem is found, replace the propeller shaft assembly.
HINT:
Double cardan joint is used on front and rear propeller shafts.