TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SA2349
SST
R11391SST
SA2348
SST
Z00641
SST
R04324
Matchmarks
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−141
1996 TOYOTA T100 (RM449U)
6. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake the staked part of the
nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
(c) Using SST, remove the companion flange.
SST 09950−30010
7. REMOVE FRONT OIL SEAL
Using SST, remove the oil seal from the differential carrier.
SST 09308−10010
8. REMOVE FRONT BEARING AND BEARING SPECER
(a) Using SST, remove the bearing from the drive pinion.
SST 09556−22010
(b) Remove the 2 washers and bearing spacer. If the front
bearing is damaged or worn, replace the bearing.
9. REMOVE DIFFERENTIAL CASE
(a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 4 bolts and bearing cap.

Downloaded from www.Manualslib.com manuals search engine R04325
SST
R02482
SST
R04326
R04327
Matchmarks SA−142
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
(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 and bearing outer race from
the carrier.
HINT:
Tag the bearing outer races to show the location for reassem-
bling.
10. REMOVE DRIVE PINION FROM DIFFERENTIAL
CARRIER
11. REMOVE DRIVE PINION REAR 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.
12. REMOVE FRONT AND REAR BEARING OUTER
RACES
NOTICE:
Do not remove the outer races except when replacing the
bearings.
Using a brass bar and hammer, remove the 2 outer races and
adjusting washer from the carrier.
HINT:
Measure the adjusting washer and note down the thickness.
13. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 ring gear set bolts.
(c) Using a plastic hammer, tap on the ring gear to separate
it from the differential case.

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R12920
SST
SST
RA0997
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−143
1996 TOYOTA T100 (RM449U)
14. CHECK DIFFERENTIAL CASE RUNOUT
(a) Install the differential case in the differential carrier (See
page SA−145).
(b) Using a dial indicator, measure the differential case run-
out.
Maximum case runout: 0.04 mm (0.0016 in.)
(c) Remove the differential case.
15. REMOVE SIDE BEARINGS
Using SST, remove the 2 side bearings from the differential
case.
SST 09950−40010, 09950−60010 (09951−00450)
HINT:
Fix the claws of SST to the notch in the differential case.
16. 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

Downloaded from www.Manualslib.com manuals search engine R04330
SST
SA0I5−01
R04331
SST SA−144
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
REPLACEMENT
REPLACE COMPANION FLANGE DUST DEFLECTOR
(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 09523−36010

Downloaded from www.Manualslib.com manuals search engine FA1121
SA0I6−02
FA1122
FA1123
FA1124
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−145
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the 2 proper thrust washers to 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.)
1.50 (0.0590)1.75 (0.0689)
1.55 (0.0610)1.80 (0.0709)
1.60 (0.0630)1.85 (0.0728)
1.65 (0.0650)1.90 (0.0748)
1.70 (0.0669)−
(b) Install the 2 side gears with the thrust washers, pinion
gears, pinion gear thrust washers and pinion shaft.
HINT:
Align the holes of the differential case and pinion shaft.
(c) Using a dial indicator, measure the side gear backlash
with holding one pinion gear toward the case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within specification, replace the thrust
washers.
(d) Using a pin punch and hammer, install the straight pin
through the holes in the differential case and pinion shaft.
(e) Using a chisel and hammer, stake the out side of the dif-
ferential case pin hole.

Downloaded from www.Manualslib.com manuals search engine R04333
SST
SST
SA1143
Boiling Water
R04332
Matchmarks
R04334
R04335
SST SA−146
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
2. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 side bearings into the differ-
ential case.
SST 09506−35010, 09950−60010 (09951−00480),
09950−70010 (09951−07150)
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.
(e) Align the matchmarks on the ring gear and differential
case.
(f) After the ring gear cools down enough, torque the set
bolts to which thread lock has been applied.
Thread lock:
Part No. 08833−00100, THREE BOND 1360K or equiv-
alent.
Torque: 125 N·m (1,270 kgf·cm, 92 ft·lbf)
4. INSPECT RING GEAR RUNOUT
(a) Install the differential case into the carrier and install the
plate washers to make sure the play in the bearing (See
page SA−57).
(b) Install bearing cap (See page SA−57).
(c) Using a dial indicator, measure the runout of ring gear.
Maximum runout: 0.05 mm (0.0020 in.)
5. INSTALL DRIVE PINION BEARING OUTER RACES
AND ADJUSTING WASHER
(a) Using SST, install a new front bearing outer race to the
carrier.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
(b) Using SST, install a new adjusting washer and install a
new rear bearing outer race to the carrier.
SST 09950−60020 (09951−00910),
09950−70010 (09951−07150)

Downloaded from www.Manualslib.com manuals search engine R00055
SST
R11163SST
SA2351
SST
SA2446
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−147
1996 TOYOTA T100 (RM449U)
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.
6. INSTALL DRIVE PINION REAR BEARING
Using SST and a press, install the rear bearing onto the drive
pinion.
SST 09506−35010
7. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion and front bearing.
HINT:
Assemble the spacer, washers and oil seal after adjusting the
gear contact 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, torque 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.
(e) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing:
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing:
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine R04453
R04535
R04558
R04453
R04455
SA−148
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
8. INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the bearing outer races on their respective bear-
ings. Make sure the left and right races are not inter-
changed.
(b) Install the differential case in the carrier.
9. ADJUST RING GEAR BACKLASH
(a) Only install the plate washer on the ring gear back side.
HINT:
Makes that the ring gear has a 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):
2WD: 0.08 − 0.13 mm (0.0031 − 0.0051 in.)
4WD: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
(d) Select a plate washer for back side ring gear, using the
backlash as reference (See page SA−145).
(e) Select a ring gear teeth side plate washer of a thickness
which eliminates any clearance between the outer race
and case.

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R04456
RA0090
R04456
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−149
1996 TOYOTA T100 (RM449U)
(f) Remove the plate washers 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:
2WD: 0.08 − 0.13 mm (0.0031 − 0.0051 in.)
4WD: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
(k) If the backlash not within specification, adjust by either in-
creasing 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.
10. ADJUST SIDE BEARING PRELOAD
(a) After adjustment with the backlash as reference, remove
the ring gear teeth side plate washer and measure the
thickness.
(b) Install a new washer of 0.06 − 0.09 mm (0.00024 − 0.0035
in.) thicker than the washer removed.
HINT:
Select a washer which can be pressed in 2/3 of the way by fin-
ger.
(c) Using a plastic hammer, tap in the plate washer.
(d) Recheck the ring gear backlash.
Backlash:
2WD: 0.08 − 0.13 mm (0.0031 − 0.0051 in.)
4WD: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
(e) If the backlash is not within specification, adjust by either
increasing or decreasing the thickness washers on both
sides by equal amount.
HINT:
The backlash will change by about 0.20 mm (0.0008 in.) with
every 0.03 mm (0.0012 in.) change in the side washer.

Downloaded from www.Manualslib.com manuals search engine R04323
SA−150
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
Washer thickness
Thickness
Mark mm (in.)Thickness
Mark mm (in.)Thickness
Mark mm (in.)
58 2.58 (0.1015) 90 2.90 (0.1142) 22 3.22 (0.1268)
60 2.60 (0.1024) 92 2.92 (0.1150) 24 3.24 (0.1276)
62 2.62 (0.1031) 94 2.94 (0.1157) 26 3.26 (0.1283)
64 2.64 (0.1039) 96 2.96 (0.1165) 28 3.28 (0.1291)
66 2.66 (0.1047) 98 2.98 (0.1173) 30 3.30 (0.1299)
68 2.68 (0.1055) 00 3.00 (0.1181) 32 3.32 (0.1307)
70 2.70 (0.1063) 02 3.02 (0.1189) 34 3.34 (0.1315)
72 2.72 (0.1071) 04 3.04 (0.1197) 36 3.36 (0.1323)
74 2.74 (0.1079) 06 3.06 (0.1205) 38 3.38 (0.1331)
76 2.76 (0.1087) 08 3.08 (0.1213) 40 3.40 (0.1339)
78 2.78 (0.1094) 10 3.10 (0.1220) 42 3.42 (0.1346)
80 2.80 (0.1102) 12 3.12 (0.1228) 44 3.44 (0.1354)
82 2.82 (0.1110) 14 3.14 (0.1236) 46 3.46 (0.1362)
84 2.84 (0.1118) 16 3.16 (0.1244) 48 3.48 (0.1370)
86 2.86 (0.1126) 18 3.18 (0.1252)−
88 2.88 (0.1134) 20 3.20 (0.1260)−
11. INSTALL BEARING CAPS
Align the matchmarks on the 2 caps and carrier and torque the
4 bolts.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
12. 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)
13. 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) Turn the companion flange in both directions to inspect
the ring gear for proper tooth contact.