TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine FA0742
FA0752
Z03861
Plate Washer
Plate Washer
FA0754
Z03848
Plate Washer
Plate Washer
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−61
1996 TOYOTA T100 (RM449U)
(e) Select a ring gear teeth side plate washer with a thickness
which eliminates any clearance between the outer race
and case.
(f) Remove the plate washes and differential case.
(g) Install the plate washer into the ring gear back side of the
carrier.
(h) Place the other plate washer onto the differential case to-
gether with the outer race, and install the differential case
with the outer race into the carrier.
(i) Tap on the ring gear with a plastic hammer so that the
washer fit to the bearing.
(j) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0070 in.)
(k) If not within specification, adjust by either increasing or
decreasing the thickness of washers on both sides by an
equal amount.
HINT:
There should be no clearance between the plate washer
and case.
Make sure that there is ring gear backlash.

Downloaded from www.Manualslib.com manuals search engine Z03863
Plate
Washer
Z03848
Plate Washer
Plate Washer
Z03852
SA−62
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
11. ADJUST SIDE BEARING PRELOAD
(a) Remove the ring gear teeth side plate washer and mea-
sure the thickness.
(b) Using the backlash as a reference, install a new washer
of 0.06 − 0.09 mm (0.0024 − 0.0035 in.) thicker than the
washer removed.
HINT:
Select a washer which can be pressed in 2/3 of the way with
your finger.
(c) Using a plastic hammer, install the plate washer.
(d) Recheck the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0070 in.)
(e) If not within specification, adjust by either increasing or
decreasing the thickness of washers on both sides by an
equal amount.
HINT:
The backlash will change by about 0.02 mm (0.0008 in.) with
every 0.03 mm (0.0012 in.) change in the plate washer.
Washer thickness
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
2.57 − 2.59 (0.1012 − 0.1020)2.81 − 2.83 (0.1106 − 0.1114)3.05 − 3.07 (0.1201 − 0.1209)
2.60 − 2.62 (0.1024 − 0.1031)2.84 − 2.86 (0.1118 − 0.1126)3.08 − 3.10 (0.1213 − 0.1220)
2.63 − 2.65 (0.1035 − 0.1043)2.87 − 2.89 (0.1130 − 0.1138)3.11 − 3.13 (0.1224 − 0.1232)
2.66 − 2.68 (0.1047 − 0.1055)2.90 − 2.92 (0.1142 − 0.1150)3.14 − 3.16 (0.1236 − 0.1244)
2.69 − 2.71 (0.1059 − 0.1067)2.93 − 2.95 (0.1154 − 0.1161)3.17 − 3.19 (0.1248 − 0.1256)
2.72 − 2.74 (0.1071 − 0.1079)2.96 − 2.98 (0.1165 − 0.1173)3.20 − 3.22 (0.1260 − 0.1268)
2.75 − 2.77 (0.1083 − 0.1091)2.99 − 3.01 (0.1177 − 0.1185)3.23 − 3.25 (0.1272 − 0.1280)
2.78 − 2.80 (0.1094 − 0.1102)3.02 − 3.04 (0.1189 − 0.1197)−
12. INSTALL BEARING CAPS
Align the matchmarks on the 2 caps and carrier.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
13. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
14. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat 3 or 4 teeth at three different positions on the ring
gear with red lead primer.
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.

Downloaded from www.Manualslib.com manuals search engine R02495
Proper ContactHeel ContactFace Contact
Toe ContactFlank Contact Select an adjusting shim that will bring the drive
pinion closer to the gear.
Select an adjusting shim that will shaft the drive
pinion gear away from the ring gear.
FA2008
Washer
Z03850
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−63
1996 TOYOTA T100 (RM449U)
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.
Washer thickness
Thickness mm (in.)Thickness mm (in.)
2.27 (0.0894)2.51 (0.0988)
2.30 (0.0906)2.54 (0.1000)
2.33 (0.0917)2.57 (0.1012)
2.36 (0.0929)2.60 (0.1024)
2.39 (0.0941)2.63 (0.1035)
2.42 (0.0953)2.66 (0.1047)
2.45 (0.0965)2.69 (0.1059)
2.48 (0.0976)−
15. INSTALL BEARING SPACER
(a) Remove the companion flange, oil slinger and rear bear-
ing (See page SA−48).
(b) Install a new bearing spacer.
(c) Install the rear bearing and oil slinger.

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SST
R11163SST
SA2351
SST
SA2352
SA−64
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
16. INSTALL OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09554−30011
Oil seal drive in depth: 1.5 mm (0.059 in.)
(b) Apply MP grease to the oil seal lip.
17. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange.
SST 09950−30010
(b) Coat the threads of a new nut with hypoid gear oil install
it.
(c) Using SST to hold the flange, tighten the nut.
SST 09330−00021
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
18. ADJUST DRIVE PINION PRELOAD
Using a torque wrench, measure the drive pinion preload using
the backlash of the drive pinion and the ring gear.
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)
If the preload is greater than the specification, replace the
spacer.
If the preload is less than the specification, retighten the nut a
little at a time with a torque of 13 N·m (130 kgf·cm, 9 ft·lbf) until
the specified preload is reached.

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SST
SA0339
SST
SA0340
SA0370
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−65
1996 TOYOTA T100 (RM449U)
Maximum torque: 235 N·m (2,400 kgf·cm, 173 ft·lbf)
If the maximum torque is exceeded while retightening the nut,
replace the spacer and repeat the preload procedure. Do not
loosen the nut to reduce the preload.
19. RECHECK RING GEAR BACKLASH
(See page SA−57)
20. RECHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−57)
21. CHECK RUNOUT OF COMPANION FLANGE (See
page SA−48)
22. STAKE DRIVE PINION NUT
23. INSTALL RH SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, install a new oil seal until its
surface is flush with the differential carrier end.
SST 09550−00032, 09950−70010 (09951−07150)
(b) Apply MP grease to the oil seal lip.
24. INSTALL RH SIDE GEAR SHAFT
(a) Install a new snap ring to the side gear shaft.
(b) Using a plastic hammer, install the side gear shaft to the
differential case.
25. CHECK INSTALLATION OF SIDE GEAR SHAFT
(a) Check that there is 2 − 3 mm (0.08 − 0.12 in.) of play in
axial direction.
(b) Check that the side gear shaft will not come out by trying
to pull it completely out by hand.
26. INSTALL INTERMEDIATE SHAFT
(a) Install a new snap ring to the shaft.
(b) Using a plastic hammer, install the shaft to the differential
case.
27. CHECK INSTALLATION OF INTERMEDIATE SHAFT
(a) Check that there is 2 − 3 mm (0.08 − 0.12 in.) of play in
the axial direction.
(b) Check that the intermediate shaft will not come out by try-
ing to pull it completely out by hand.

Downloaded from www.Manualslib.com manuals search engine SA0371
SA0400
R11760
FIPG
SA0374
SA−66
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
28. INSTALL CLUTCH CASE TO SIDE GEAR SHAFT TUBE
(a) Install a new O−ring to the tube.
(b) Coat the O−ring with MP grease.
(c) Install the clutch case to the tube.
(d) Using a torx socket (E14), torque the 2 torx bolts.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
29. INSTALL CLUTCH SLEEVE
30. INSTALL LH SIDE GEAR SHAFT TO DIFFERENTIAL
CARRIER
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the differential carrier and
clutch case.
(b) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(c) Apply FIPG to the carrier, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the side gear shaft within 10 minutes after applying FIPG.
(d) Install LH side gear shaft to the differential carrier.
(e) Using a torx socket (E14), torque the 4 torx bolts.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine R11761
FIPG
Seal Width Approx.
1 − 2 mm (0.04 − 0.08 in.)
R11762
FIPG
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−67
1996 TOYOTA T100 (RM449U)
31. INSTALL DIFFERENTIAL CARRIER COVER
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the differential carrier and
carrier cover.
(b) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(c) Apply FIPG to the carrier cover, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the carrier cover within 10 minutes after applying FIPG.
(d) Install the differential carrier cover with the 8 bolts.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
32. INSTALL A.D.D. ACTUATOR
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the actuator and clutch case.
(b) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(c) Apply FIPG to the clutch case, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the actuator within 10 minutes after applying FIPG.
(d) Torque the 4 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine SA0G9−01
SA−68
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−47).
AFTER INSTALLATION, FILL DIFFERENTIAL WITH HYPOID GEAR OIL (See page SA−43)

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F01743
Differential
A.D.D. Indicator Switch
ActuatorVacuum TankTransfer Indicator SwitchA.D.D. Relay 4WD Indicator A.D.D. Solenoids
(VSV2 and VSV4)
− SUSPENSION AND AXLEA.D.D. CONTROL SYSTEM
SA−69
1508 Author: Date:
1996 TOYOTA T100 (RM449U)
A.D.D. CONTROL SYSTEM
LOCATION

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SA0356
SA0361
SA0362
Port A
SA0363
Port B
SA0383
SA−70
− SUSPENSION AND AXLEA.D.D. CONTROL SYSTEM
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT CLUTCH HUB AND CLUTCH SLEEVE
(a) Check the clutch hub and clutch sleeve for wear and dam-
age.
(b) Check that clutch sleeve sides smoothly on the clutch
hub.
2. MEASURE CLEARANCE OF SLEEVE FORK AND
CLUTCH SLEEVE
Using a feeler gauge, measure the clearance between the
sleeve fork and the clutch sleeve.
Maximum clearance: 0.35 mm (0.0138 in.)
3. INSPECT A.D.D. ACTUATOR
(a) Check that the sleeve fork moves to the actuator side
when a vacuum of 66.7 kPa (500 mmHg, 19.69 in.Hg) is
applied to the port A. Also check that the vacuum remains
constant.
(b) Check that the sleeve fork moves away from the actuator
when a vacuum of 66.7 kPa (500 mmHg, 19.69 in.Hg) is
applied to port B. Also check that the vacuum remains
constant.
4. INSPECT A.D.D. SOLENOIDS
(a) Using an ohmmeter, measure the resistance of the sole-
noids.
Resistance: 37 − 44 Ω