TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SR07Y−01
F00854
SSTSST
Oil Seal
SST Vinyl Tape
W03126
Rack Teeth End
SST SR−64
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR MOLYBDE-
NUM DISULFIDE LITHIUM BASE GREASE (See page
SR−54)
2. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950−60010 (09951−00240, 09951−00430,
09952−06010), 09950−70010 (09951−07360)
NOTICE:
Make sure to install the oil seal facing the correct
direction.
Take care that the oil seal does not get reversed as
you install it.
3. INSTALL STEERING RACK
HINT:
If necessary, scrape the burrs off the rack teeth end then clean
and burnish before installation.
(a) Make sure that the tube hole is not clogged with grease.
HINT:
If the tube hole is clogged, the pressure inside the boot will
change after it is assembled and the steering wheel turned.
(b) Install SST to the rack.
SST 09631−33010
(c) Coat SST with power steering fluid.
(d) Insert the rack into the rack housing.
NOTICE:
Be careful not to damage the oil seal lip.
(e) Remove the SST.

Downloaded from www.Manualslib.com manuals search engine R13021
Vinyl Tape
R15248
Wire
SST
Cylinder End
Stopper
R04609
SST
R13031
Vinyl Tape
W03369
SST
Oil Seal
− STEERINGPOWER STEERING GEAR (2WD)
SR−65
1996 TOYOTA T100 (RM449U)
4. INSTALL RACK BUSHING AND CYLINDER END
STOPPER
(a) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(b) Coat a new O−ring with power steering fluid and install it
to the bushing.
(c) Push in the bushing.
NOTICE:
Make sure to install the bushing facing the correct direc-
tion.
(d) Push in the cylinder end stopper until the wire installation
hole appears.
5. INSTALL WIRE
(a) Insert a new wire end into the hole of the rack housing.
(b) Using SST, turn the cylinder end stopper clockwise until
the wire end disappears.
SST 09631−10021
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631−12071
(b) Apply 53.3 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the valve shaft.
(c) Install the valve assembly into the control valve housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.
8. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09612−22011
NOTICE:
Make sure to install the oil seal facing the correct direction.

Downloaded from www.Manualslib.com manuals search engine R04613
SST
R05209
SR−66
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
9. INSTALL CONTROL VALVE HOUSING WITH CON-
TROL VALVE ASSEMBLY
(a) Place a new gasket on the rack housing.
(b) Torque the 2 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
10. INSTALL DUST COVER
11. INSTALL SELF−LOCKING NUT
Using SST to stop the control valve assembly, install a new self−
locking nut.
SST 09616−00010
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
12. INSTALL RACK HOUSING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the rack housing cap.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(c) Using a center punch, stake the cap at 2 places.
13. INSTALL RACK GUIDE, RACK GUIDE SPRING AND
RACK GUIDE SPRING CAP
(a) Apply sealant to 2 or 3 threads of the spring cap.
Sealant: Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Temporarily install the spring cap.
14. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporariry install the RH and LH rack ends.
(b) Set the steering rack at the rack stroke center.
(c) Fix the steering gear in a vise so that the rack guide spring
cap faces straight up.
(d) Using a hexagon wrench (21 mm), torque the rack guide
spring cap.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine R15451
Approxmately 60°
R14222
SST
R15454
Dial Indicator
Level Tip
Dial
Indicator
15mm
(0.59in.)
Steering Rack
− STEERINGPOWER STEERING GEAR (2WD)
SR−67
1996 TOYOTA T100 (RM449U)
(e) Using a hexagon wrench (21 mm), return the rack guide
spring cap approximately 60°.
(f) Using SST, rotate the control valve assembly to operate
the steering rack 2 or 3 times through its full stroke.
SST 09616−00010
(g) Firmly fix the dial indicator in position so that the dial indi-
cator tip touches the top of the steering rack, as shown.
HINT:
Fix the magnetic stand of the dial indicator to the rack
housing.
Use a level tip for the dial indicator tip.

Downloaded from www.Manualslib.com manuals search engine R15452
Steering Twist of Steering Rack
Steering Rack Center Position
Dial Indicator
0.08mm(0.0032in.) or less (55kgf·cm, 4.8in.·lbf)
SST
Torque
Wrench
Fulcrum
LengthSST 90°
180°Value Control Rack Dial Indicator
Shaft SST Clockwise Counterclckwise
90°
180° 5.4N·m SR−68
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
(h) Using a hexagon wrench (21 mm), gradually tighten the
rack guide spring cap and adjust the twist of the steering
rack to 0.08 mm (0.0032 in.) or less when the rack is
twisted clockwise and counterclockwise by SST and
torque wrench with 5.4 N·m (55 kgf·cm, 48 in.·lbf) of
torque applied.
SST 09922−10010
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion
HINT:
Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
(i) Using SST to ratate the control valve shaft, adjust the
twist of the rack so that it is within the above specifications
at the following 5 points:
SST 09616−00010
(1) Steering rack at center position.
(2) Steering pinion shaft rotated 90° clockwise from the
center position.
(3) Steering pinion shaft rotated 90° counterclockwise
from the center position.
(4) Steering pinion shaft rotated 180° clockwise from
the center position.
(5) Steering pinion shaft rotated 180° counterclock-
wise from the center position.

Downloaded from www.Manualslib.com manuals search engine R14224
Fulcrum
Length
SST
Hexagon Wrench
R14225
SST
Z14297
SST
Length Fulcrum
R04619
− STEERINGPOWER STEERING GEAR (2WD)
SR−69
1996 TOYOTA T100 (RM449U)
(j) Apply sealant to 2 or 3 threads of the rack guide spring
cap lock nut.
Sealant: Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(k) Using a hexagon wrench (21 mm) to hold the rack guide
spring cap, and using SST, install and torque the lock nut.
SST 09922−10010
Torque: 51 N·m (521 kgf·cm, 38 ft·lbf)
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(l) Repeat (h)
15. CHECK TOTAL PRELOAD
(a) Using SST and a torque wrench, check the total preload.
SST 09616−00010
Preload (turning):
0.5 − 1.4 N·m (5 − 14 kgf·cm, 4.3 − 12.2 in.·lbf)
HINT:
The total preload must be within the specification throughout
the full stroke of the steering rack.
If it is not within specification, adjust the total preload again.
(b) Remove the RH and LH rack ends.
16. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner to hold the steering rack steady, and us-
ing SST, torque the rack end.
SST 09922−10010
Torque: 61 N·m (618 kgf·cm, 45 ft·lbf)
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Using a brass bar and hammer, stake the washer.
NOTICE:
Avoid any impact to the rack.

Downloaded from www.Manualslib.com manuals search engine R04620
R04621
28−8°
2−5 mm
(0.08−0.20in.)
R15216
SST
Fulcrum
Length SR−70
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
17. INSTALL RH AND LH RACK BOOTS, CLAMPS AND
CLIPS
(a) Make sure that the tube hole is not clogged with grease.
HINT:
If the tube hole is clogged, the pressure inside the boot will
change after it is assembled and the steering wheel turned.
(b) Install the boot.
NOTICE:
Be careful not to damage or twist the boot.
(c) Tighten the clamp and clip, as shown in the illustration.
18. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe−in, torque the lock nut (See page
SA−7).
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
19. INSTALL 2 TURN PRESSURE TUBES
(a) Coat 2 new O−rings with power steering fluid and install
them to the tube.
(b) Using SST, install and torque the tube.
SST 09633−00020
Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
(c) Install the clamp plate with the bolt.

Downloaded from www.Manualslib.com manuals search engine SR07Z−01
R15251
SST
Fulcum Length
− STEERINGPOWER STEERING GEAR (2WD)
SR−71
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
Torque the 2 gear assembly set bolts and nut.
2. INSTALL MOUNT BRACKET AND GROMMET
(a) Install the grommet and mount bracket to the PS gear as-
sembly.
(b) Torque the 2 bolts.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
3. CONNECT PRESSURE FEED TUBE AND INSTALL
RETRUN TUBE
(a) Coat a new O−ring with power steering fluid and install it
to the tube.
(b) Using SST, connect the pressure feed tube and install the
return tube.
SST 09631−22020
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT RETURN HOSE
5. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
6. CONNECT RH AND LH TIE ROD ENDS
Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
7. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
8. CENTER SPIRAL CABLE
(See page SR−20)
9. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering column
main shaft.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
10. BLEED POWER STEERING SYSTEM
(See page SR−4)
11. CHECK STEERING WHEEL CENTER POINT
12. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
13. INSTALL STEERING WHEEL PAD
(See page SR−20)
14. CHECK FRONT WHEEL ALIGNMENT
(See page SA−7)

Downloaded from www.Manualslib.com manuals search engine R15457
Return Tube
Intermediate Shaft Assembly
Pressure Feed Tube
PS Gear Assembly
Pitman Arm Sub−Assembly
With Relay Rod
Spring Washer 44 (450, 33)
*36 (365, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
35 (360, 26)
44 (450, 33)
*36 (365, 26)
142 (1450, 105)
177 (1800, 130)
SR080−01
SR−72
− STEERINGPOWER STEERING GEAR (4WD)
1746 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING GEAR (4WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Z18651
 Washer
 O−Ring
 No.1 Lock Nut Side Cover No.1 Hose Support Bracket Adjusting Screw Lock Nut
Sector Shaft Adjusting Screw
Cross Shaft
Power Piston
Plunger Guide Nut
Compression Spring
Power Piston Plunger
Power Piston Plunger Guide
Power Steering Gear HousingNeedle Roller Bearing
 Union Seat
 O−Ring
 Teflon RingWorm Gear Valve
Body Assembly
Metal Spacer
 Snap ring
Non−reusable part
Power Steering fluid
Molybdenum disulfide lithium base grease  O−Ring
 O−Ring
 Teflon Ring
 Oil Seal
61 (620, 45)
61 (620, 45)
: Specified torque
N·m (kgf·cm, ft·lbf)
46 (470, 34)
20 (205, 15)
− STEERINGPOWER STEERING GEAR (4WD)
SR−73
1747 Author: Date:
1996 TOYOTA T100 (RM449U)