TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SA2348
SST
Z00641
SST
Z03859
Matchmarks
FA0751
SST
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−51
1996 TOYOTA T100 (RM449U)
16. REMOVE OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal from the differential carrier.
SST 09308−10010
(b) Remove the oil slinger.
17. REMOVE REAR BEARING AND BEARING SPACER
(a) Using SST, remove the rear bearing from the drive pinion.
SST 09556−30010
(b) Remove the bearing spacer.
18. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 4 bolts and 2 bearing caps.
(c) Using SST and a hammer, remove the 2 side bearing
plate washers.
SST 09504−22011
HINT:
Measure the plate washer and note down the thickness.
(d) Remove the differential case with the bearing outer races
from the differential carrier.
HINT:
Tag the bearing outer races to show the location for reassem-
bling.
19. REMOVE DRIVE PINION FROM DIFFERENTIAL CAR-
RIER

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SST
W00401
Front Rear
FA1998
Matchmarks
R11392
SST
SST SA−52
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
20. REMOVE DRIVE PINION FRONT BEARING
Using SST and a press, remove the bearing from the drive pin-
ion.
SST 09950−00020
HINT:
If the drive pinion or ring gear are damaged replace them as a
set.
21. REMOVE DRIVE PINION BEARING OUTER RACES
Using a brass bar and hammer, remove the 2 outer races from
the differential carrier.
22. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Using a screwdriver and hammer, unstake the lock plates.
(c) Remove the 10 bolts and 5 lock plates.
(d) Using a plastic hammer, tap on the ring gear to separate
it from the differential case.
23. REMOVE SIDE BEARINGS
Using SST, remove the 2 side bearings from the differential
case.
SST 09950−40010, 09950−60010 (09951−00480)
HINT:
Fix the claws of SST to the notch in the differential case.
24. DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove these parts from the differential case:
Pinion shaft
2 pinion gears
2 pinion gear thrust washers
2 side gears
2 side gear thrust washers

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− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−53
1996 TOYOTA T100 (RM449U)
(c) Using a brass bar and hammer, remove the 2 bearings.

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SA0G7−02
R04348
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Z03857
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SA0358
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R04655
SST SA−54
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REPLACE COMPANION FLANGE DUST DEFLECTOR,
IF NECESSARY
(a) Using SST and a press, remove the dust deflector.
SST 09950−00020
(b) Using SST and a press, install a new dust deflector.
SST 09636−20010
2. REPLACE SIDE GEAR SHAFT, IF NECESSARY
(a) Remove the clutch hub.
(1) Using a snap ring expander, remove the snap ring.
(2) Remove the clutch hub from the side gear shaft.
(b) Remove the LH side gear shaft from the tube.
(1) Remove the 3 bearing retainer bolts.
(2) Remove the side gear shaft from the tube.
(c) Replace the LH side gear shaft bearing and dust cover.
(1) Using a snap ring expander, remove the snap ring.
(2) Using SST and a press, remove the bearing.
SST 09950−00020
(3) Remove the bearing retainer.
(4) Using a screwdriver and hammer, remove the dust
cover.
(5) Using SST and a press, install a new dust cover.
SST 09316−20011
(6) Install the bearing retainer.

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SST
SA0334SST
SA0398
SA0399
SST
SA0335
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−55
1996 TOYOTA T100 (RM449U)
(7) Using SST and a press, install a new bearing.
SST 09316−60011 (09316−00041)
(8) Using a snap ring expander, install a new snap ring.
(d) Replace the LH side oil seal.
(1) Using SST, remove the side oil seal.
SST 09308−00010
(2) With the oil seal lip facing upward, use press and
plate to press in a new oil seal until its end is flush
with the surface of the tube.
(3) Using SST and a press, install the oil seal.
SST 09554−14010
Oil seal drive in depth: 2.5 mm (0.098 in.)
(4) Coat the lip of oil seal with MP grease.
(e) Install the LH side gear shaft to the tube.
(1) Install the side gear shaft into the tube.
(2) Torque the 3 bearing retainer bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(f) Install the clutch hub.
(1) Install the clutch hub to the shaft.
(2) Using a snap ring expander, install a new snap ring.

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SST
SA0366
SA−56
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
(g) Repalce the RH side gear shaft dust cover.
(1) Using a screwdriver and hammer, remove the dust
cover.
(2) Using SST and a press, install a new dust cover.
SST 09710−30055
3. REPLACE A.D.D. ACTUATOR, IF NECESSARY
(a) Remove the A.D.D. indicator switch.
(b) Remove the sleeve fork pin.
(1) Using a hexagon wrench, remove the screw plug.
(2) Using a pin punch and hammer, remove the pin
through the hole of clutch case cover.
(c) Seperate A.D.D. actuator from the clutch case cover and
remove the sleeve fork.
(1) Using a hexagon wrench, remove the screw plug.
(2) Remove the spring seat, spring and steel ball.
(3) Remove the 2 bolts and actuator from the clutch
case cover.
(4) Separate the actuator from the clutch case cover
and remove the sleeve fork.
(5) Remove the O−ring from the actuator.
(d) Install the sleeve fork and A.D.D. actuator into the clutch
case cover.
(1) Install the new O−ring to the actuator.
(2) Coat the O−ring with MP grease.
(3) Place the sleeve fork and install the actuator to the
clutch case cover.
(4) Torque the 2 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(5) Install the steel ball, spring and spring seat.
(6) Coat the threads of screw plug with FIPG.
FIPG:
Part No.08826−00090, THREE BOND 1281 or equiva-
lent
(7) Using a hexagon wrench, install the screw plug.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(e) Install the sleeve fork pin.
(1) Using a pin punch and hammer, install the pin
through the hole of clutch case cover.
(2) Using a hexagon wrench, install the screw plug.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

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SA0G8−03
SA0355
SST
FA1121
FA1123
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−57
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE
(a) Using SST and a press, install 2 new needle bearings.
SST 09950−60010 (09951−00370),
09950−70010 (09951−07150)
Bearing press in depth: 2.0 mm (0.079 in.)
(b) Install the 2 proper thrust washers on the side gears.
HINT:
Refer to the table below to select thrust washers which will en-
sure that the backlash is within specifications.
Washer thickness
Thickness mm (in.)Thickness mm (in.)
0.96 − 1.04 (0.0378 − 0.0409)1.16 − 1.24 (0.0457 − 0.0488)
1.06 − 1.14 (0.0417 − 0.0449)1.26 − 1.34 (0.0496 − 0.0528)
(c) Install the 2 side gears, pinion gears, pinion gear thrust
washers and pinion shaft in the differential case.
HINT:
Align the holes of the differential case and pinion shaft.
(d) Using a dial indicator measure the side gear backlash
with holding one pinion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install side gear
thrust washers with different thicknesses.

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SA2160
Boiling Water
Z02483 FA1128
FA1129
SA1395
SST
SST SA−58
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
2. INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL
CASE
(a) Using a pin punch and hammer, install the straight pin
through the differential case and hole of the pinion shaft.
(b) Using a chisel and hammer, stake the out side of the dif-
ferential case pin hole.
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and
ring gear.
(b) Heat the ring gear to about 100°C (212°F) in boiling wa-
ter.
(c) Carefully take the ring gear out of the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the ring gear and differential case.
(e) Temporarily install 5 new lock plates and 10 bolts so that
the bolt holes in the ring gear and differential case are not
misaligned.
(f) After the ring gear has cooled sufficiently, torque the 10
ring gear set bolts.
Torque: 97 N·m (985 kgf·cm, 71 ft·lbf)
(g) Using a chisel and hammer, stake the 5 lock plates.
HINT:
Stake the claw so that it is flush with the flat surface of the bolt.
For the claw contacting the protruding portion of the bolt, stake
only the half of it on the tightening side.
4. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 bearings into the differential
case.
SST 09226−10010, 09550−10012 (09558−10010)

Downloaded from www.Manualslib.com manuals search engine Z03851
W00404
SST Front Rear
R01197
SST
R11163SST
SA2347
SST
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−59
1996 TOYOTA T100 (RM449U)
5. CHECK RING GEAR RUNOUT
(a) Install the differential case onto the carrier and install the
2 plate washers to fill the play in the bearing (See page
SA−57).
(b) Install 2 bearing caps (See page SA−57).
(c) Using a dial indicator, measure the runout of ring gear.
Maximum runout: 0.07 mm (0.0028 in.)
6. INSTALL DRIVE PINION FRONT AND REAR BEARING
OUTER RACES
(a) Using SST and a press, install the front side of the outer
race.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
(b) Using SST and a press, install the rear side of the outer
race.
SST 09950−60020 (09951−00790),
09950−70010 (09951−07150)
7. INSTALL DRIVE PINION FRONT BEARING
(a) Install the washer on the drive pinion.
HINT:
First fit a washer with the same thickness as the washer which
was removed, then after checking the tooth contact pattern, re-
place the washer with one of a different thickness if necessary.
(b) Using SST, install the front bearing onto the drive pinion.
SST 09506−30012
8. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion, rear bearing and oil slinger.
HINT:
Assemble the spacer and oil seal after adjusting the gear con-
tact pattern.
(b) Using SST, install the companion flange.
SST 09950−30010
(c) Coat the threads of the nut with hypoid gear oil.
(d) Adjust the drive pinion preload by tightening the compan-
ion flange nut.
Using SST to hold the flange, tighten the nut.
SST 09330−00021
NOTICE:
As there is no spacer, tighten the nut a little at a time, being
careful not to overtighten it.

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FA0743
FA0744
FA0746
FA0743
SA−60
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
(e) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing:
1.2 − 1.9 N·m (12 − 19 kgf·cm, 10.4 − 16.5 in.·lbf)
Reused bearing:
0.6 − 1.0 N·m (6 − 10 kgf·cm, 5.2 − 8.7 in.·lbf)
9. INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL
CARRIER
(a) Place the 2 bearing outer races on their respective bear-
ings. Check that the left and right outer races are not inter-
changed.
(b) Install the differential case in the differential carrier.
10. ADJUST RING GEAR BACKLASH
(a) Only install the plate washer on the ring gear back side.
HINT:
Make sure that the ring gear has backlash.
(b) Tap on the ring gear with a plastic hammer so that the
washer fit to the bearing.
(c) Using a dial indicator, measure the side gear backlash
with holding one pinion gear toward the differential case.
Backlash (reference): 0.13 mm (0.0051 in.)
(d) Select a plate washer for back side ring gear, using the
backlash as reference (See page SA−57).