TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SR081−01
R08049
SST
R12957
SST SR−74
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD
(See page SR−13)
3. REMOVE STEERING WHEEL
(See page SR−13)
4. DISCONNECT PITMAN ARM SUB−ASSEMBLY WITH
RELAY ROD
(a) Remove the pitman arm set nut and spring washer.
(b) Using SST, disconnect the pitman arm from the gear as-
sembly.
SST 09628−62011
5. DISCONNECT PRESSURE FEED TUBE AND RETURN
TUBE
Using SST, disconnect the tube.
SST 09631−22020
6. DISCONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−13)
7. REMOVE PS GEAR ASSEMBLY
Remove the 3 bolts, nuts and washers.

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R01279
SST
R01292
R01293
Z14397
Hexagon
Wrench
R15243
SST
− STEERINGPOWER STEERING GEAR (4WD)
SR−75
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtightn it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Mount the gear assembly on SST and clamp SST in a vise.
SST 09630−00014 (09631−00142)
2. REMOVE ADJUSTING SCREW LOCK NUT AND SEAL
WASHER
3. REMOVE SIDE COVER
(a) Remove the 4 bolts and No.1 hose support bracket.
(b) Using a screwdriver, turn the sector shaft adjusting screw
clockwise until the cover comes off.
(c) Remove the O−ring from the cover.
4. REMOVE SECTOR SHAFT
Using a plastic hammer, tap on the sector shaft end and pull out
the shaft.
5. REMOVE POWER PISTON PLUNGER GUIDE NUT,
COMPRESSION SPRING, POWER PISTON PLUNGER
AND POWER PISTON PLUNGER GUIDE
(a) Using a hexagon wrench (10 mm), remove the plunger
guide nut.
(b) Remove the O−ring from the plunger guide nut.
6. REMOVE WORM GEAR VALVE BODY ASSEMBLY
(a) Remove the 4 bolts.
(b) Using SST, turn the valve body shaft clockwise with hold-
ing the power piston nut by your finger so it cannot move.
SST 09616−00010
(c) Pull out the valve body assembly.
NOTICE:
Ensure that the power piston nut does not come off the
worm shaft.
(d) Remove the 2 O−rings from the gear housing.

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Z14503
Dial Indicator
30 mm
(1.18 in.)
Z14504
Dial
Indicator
R01297
R01283
SST
Z06211 SR3019 SR3020
SR−76
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT BALL CLEARANCE
Using a dial indicator, check the ball clearance. Move the power
piston nut up and down.
Maximum clearance: 0.15 mm (0.0059 in.)
2. INSPECT SECTOR SHAFT ADJUSTING SCREW
THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.03 − 0.05 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.05 mm (0.0020 in.)
3. IF NECESSARY, ADJUST SECTOR SHAFT
ADJUSTING SCREW THRUST CLEARANCE
(a) Using a chisel and hammer, unstake the No.1 lock nut.
(b) Using SST, remove the No.1 lock nut.
SST 09630−00014 (09631−00051)
(c) Using a screwdriver, adjust the adjusting screw for the
correct thrust clearance.
(d) Tighten a new lock nut.
(e) Stake the lock nut.
4. IF NECESSARY, REPLACE 2 NEEDLE ROLLER
BEARINGS
(a) Using a screwdriver, pry out the oil seal from the gear
housing.
(b) Using snap ring pliers, remove the snap ring from the gear
housing.
(c) Remove the metal spacer, teflon ring and O−ring from the
gear housing.

Downloaded from www.Manualslib.com manuals search engine Z14505
SST
Bearing
R14227
SST
SST
Bearing
R14228
Bearing SST 23.1 mm
(0.909 in.)SST
SST SST
R14324
SST
Bearing 89.0 mm
(3,504 in.)
SST
SST SST
− STEERINGPOWER STEERING GEAR (4WD)
SR−77
1996 TOYOTA T100 (RM449U)
(d) Using SST, remove the bearing from the gear housing.
SST 09612−65014 (09612−01030)
(e) Using SST, press out the bearing from the gear housing.
SST 09950−60010 (09951−00360, 09951−00420,
09952−06010), 09950−70010 (09951−07200)
(f) Coat a new bearing with molybdenum disulfide lithium
base grease.
(g) Using SST, press in the bearing, as shown in the illustra-
tion.
SST 09950−60010 (09951−00360, 09951−00420,
09952−06010), 09950−70010 (09951−07200)
(h) Coat a new bearing with molybdenum disulfide lithium
base grease.
(i) Using SST, press in the bearing, as shown in the illustra-
tion.
SST 09950−60010 (09951−00360, 09951−00420,
09952−06010), 09950−70010 (09951−07200)
(j) Coat a new O−ring and metal spacer with power steering
fluid.
(k) Install the O−ring and metal spacer.
(l) Using snap ring pliers, install a new snap ring.
(m) Coat a new teflon ring with power steering fluid.
(n) Form the teflon ring into a heart shape and install it by
hand.

Downloaded from www.Manualslib.com manuals search engine Z06212
SST
SR3026 SR3004
W03370
SST
Oil Seal
SST
R01298
SR2804
SR−78
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
(o) Using SST, form the teflon ring.
SST 09630−00014 (09631−00121)
NOTICE:
The teflon ring must be squeezed before inserting the sec-
tor shaft or damage will result.
(p) Coat a new oil seal lip with power steering fluid.
(q) Using SST, drive the oil seal into the gear housing.
SST 09950−60010 (09951−00340, 09951−00430,
09952−06010), 09950−70010 (09951−07200)
NOTICE:
Make sure to install the oil seal facing the correct direction.
5. IF NECESSARY, REPLACE TEFLON RING AND
O−RING
(a) Using a screwdriver, remove the teflon ring and O−ring
from the worm gear valve body assembly.
NOTICE:
Be careful not to damage the worm gear valve body assem-
bly.
(b) Coat a new O−ring with power steering fluid and install it.
(c) Expand a new teflon ring with your fingers.
NOTICE:
Be careful not to overexpand the teflon ring.
(d) Install the teflon ring.
(e) Coat the teflon ring with power steering fluid and snug it
down with a piston ring compressor for 5 − 7 minutes.

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Screw Extractor
SR2811
− STEERINGPOWER STEERING GEAR (4WD)
SR−79
1996 TOYOTA T100 (RM449U)
6. IF NECESSARY, REPLACE UNION SEATS
(a) Using a screw extractor, remove the 2 union seats from
the worm gear valve body assembly.
(b) Using a hammer and an extension bar, tap in 2 new union
seats.
NOTICE:
Before installing the union seat, remove dust sticking to
the worm gear valve body assembly.

Downloaded from www.Manualslib.com manuals search engine SR084−01
R15586
R15587
SST
R12202
Hexagon
Wrench SR−80
− STEERINGPOWER STEERING GEAR (4WD)
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−72)
2. INSTALL WORM GEAR VALVE BODY ASSEMBLY
(a) Coat 2 new O−rings with power steering fluid and install
them to the gear housing.
(b) Install the valve body assembly into the gear housing.
NOTICE:
Ensure that the power piston nut does not come off
the worm shaft.
Be careful not to damage the teflon ring.
(c) Torque the 4 bolts.
Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
(d) Using SST and a torque wrench, check the valve body as-
sembly rotating torque.
SST 09616−00010
Rotating torque:
0.3 − 0.5 N·m (3 − 5.5 kgf·cm, 2.6 − 4.8 in.·lbf)
HINT:
Hold the worm gear to prevent it from turning.
If rotating torque is not correct, replace the worm gear valve
body assembly.
3. INSTALL POWER PISTON PLUNGER GUIDE, POWER
PISTON PLUNGER, COMPRESSION SPRING AND
POWER PISTON PLUNGER GUIDE NUT
(a) Coat a new O−ring with power steering fluid and install it
to the plunger guide nut.
(b) Install the plunger guide nut with a hexagon wrench (10
mm).
Torque: 20 N·m (205 kgf·cm, 15 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine R01241
R01286
SST
Matchmarks
R01287
SST
R01290
− STEERINGPOWER STEERING GEAR (4WD)
SR−81
1996 TOYOTA T100 (RM449U)
4. INSTALL SECTOR SHAFT AND SIDE COVER
(a) Coat a new O−ring with power steering fluid and install it
the side cover.
(b) Assemble the sector shaft to the side cover.
HINT:
Fully loosen the sector shaft adjusting screw.
(c) Set the power piston nut at the center of the gear housing.
(d) Install and push the sector shaft into the gear housing so
that the center teeth mesh together.
(e) Torque the 4 bolts in a diagonal pattern.
Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
5. DETERMINE CENTER POSITION
(a) Using SST, turn the worm gear valve body shaft so full
lock in both directions and determine the exact center.
SST 09616−00010
(b) Place matchmarks on the worm gear valve body shaft and
gear housing to show neutral position.
6. ADJUST SECTOR SHAFT ADJUSTING SCREW
(a) Install SST with a torque wrench on the worm gear valve
body shaft.
SST 09616−00010
(b) Turn the adjusting screw until the preload is within the
specification.
Preload (Turning):
0.2 − 0.4 N·m (2 − 4 kgf·cm, 1.7 − 3.5 in.·lbf)
7. INSTALL NEW SEAL WASHER
8. INSTALL ADJUSTING SCREW LOCK NUT
Torque the lock nut while holding the sector shaft adjusting
screw.
Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine R01288
SST SR−82
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
9. CHECK TOTAL PRELOAD
Using SST and a torque wrench, check total preload.
SST 09616−00010
Total preload (Turning):
0.5 − 0.9 N·m (5 − 9.5 kgf·cm, 4.3 − 8.3 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine SR085−01
R15509
Fulcrum
Length
SST
SR2922
Alignment Marks
− STEERINGPOWER STEERING GEAR (4WD)
SR−83
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Install the 3 bolts, washers and nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
2. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
3. CONNECT PRESSURE FEED TUBE AND RETURN
TUBE
Using SST, connect the tube.
SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT PITMAN ARM SUB−ASSEMBLY WITH
RELAY ROD
(a) Align the alignment marks on the pitman arm and sector
shaft, and connect the pitman arm.
(b) Install the spring washer and pitman arm set nut.
Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
5. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
6. CENTER SPIRAL CABLE
(See page SR−20)
7. 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.
8. BLEED POWER STEERING SYSTEM
(See page SR−4)
9. CHECK STEERING WHEEL CENTER POINT
10. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
11. INSTALL STEERING WHEEL PAD
(See page SR−20)
12. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)