TOYOTA T100 1996 Factory Service Manual

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RH Tie Rod End
Sub−Assembly
RH Knuckle Arm
Steering Damper
 Non−reusable partEngine Under CoverSpring WasherPitman ArmLH Knuckle Arm LH Tie Rod Sub−Assembly
LH Tie Rod End Assembly RH Tie Rod
Idler Arm
Assembly
Relay Rod
 Cotter PinLH Tie Rod
Assembly Clamp
Tie Rod
Clamp
Clamp
Tie Rod
Clamp
Sub−Assembly
Sub−Assembly RH Tie Rod
 
 22 (225, 16)
22 (225, 16)
22 (225, 16)
22 (225, 16)
90 (920, 67)
177 (1800, 130)
90 (920, 67)
25 (260, 19)
59 (600, 43)
90 (920, 67)
90 (920, 67)
142 (1450, 105)
: Specified torque
N·m (kgf·cm, ft·lbf)
59 (600, 43)
SR086−01
SR−84
− STEERINGSTEERING LINKAGE
1758 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING LINKAGE
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine SR087−01
R08049
SST
R15244
SST
R04470
SST
SR1254
SST
SR1260
SST
− STEERINGSTEERING LINKAGE
SR−85
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE ENGINE UNDER COVER
Remove the 4 bolts.
2. REMOVE PITMAN ARM
(a) Remove the pitman arm set nut and spring washer.
(b) Using SST, disconnect the pitman arm from the cross
shaft.
SST 09628−62011
(c) Remove the cotter pin and nut.
(d) Using SST, disconnect the pitman arm from the relay rod.
SST 09611−22012
3. REMOVE LH AND RH TIE ROD ASSEMBLIE
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod assembly from the relay
rod.
SST 09628−62011
(c) Remove the cotter pin and nut.
(d) Using SST, disconnect the tie rod assembly from the
knuckle arm.
SST 09610−20012
4. REMOVE RH AND LH TIE ROD SUB−ASSEMBLIES,
TIE ROD END SUB−ASSEMBLIES, TIE RODS AND 2
CLAMPS
Remove the 2 bolts, washers and nuts.
5. REMOVE STEERING DAMPER
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the steering damper from the relay
rod.
SST 09611−22012
(c) Remove the bolt and nut.

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SST SR−86
− STEERINGSTEERING LINKAGE
1996 TOYOTA T100 (RM449U)
6. REMOVE IDLER ARM ASSEMBLY
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the idler arm from the relay rod.
SST 09610−20012
(c) Remove the 3 bolts, washers and nuts.

Downloaded from www.Manualslib.com manuals search engine SR088−02
R08100
AA = A’
B = B’ BB’ A’
Z03912
Front
Front
SR0262 SR1454
− STEERINGSTEERING LINKAGE
SR−87
1996 TOYOTA T100 (RM449U)
INSTALLATION
HINT:
When connecting the ball stud to the arm or rod, remove the
grease on the joint surfaces.
1. INSTALL IDLER ARM ASSEMBLY
(a) Install the 3 bolts, washers and nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
(b) Connect the idler arm to the relay rod.
(c) Install the nut and a new cotter pin.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
2. INSTALL STEERING DAMPER
(a) Torque the bolt and nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(b) Install the nut and a new cotter pin.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
3. INSTALL RH AND LH TIE ROD SUB−ASSEMBLIES,
TIE ROD END SUB−ASSEMBLIES, TIE ROD AND 2
CLAMPS
(a) Screw the tie rod end sub−assembly and tie rod sub−as-
sembly into the tie rod.
HINT:
The tie rod assembly length should be approximately 329.2 mm
(12.961 in.), and the remaining length of threads on both RH
and LH tie rod assemblies should be equal.
(b) Turn the tie rod end sub−assembly so that they cross at
about 90 degrees.
(c) After adjusting toe−in, torque the bolt.
(See page SA−10)
Torque: 22 N·m (225 kgf·cm, 16 ft·lbf)
4. INSTALL RH AND LH TIE ROD ASSEMBLIES
(a) Connect the tie rod assembly to the knuckle arm.
(b) Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
(c) Connect the tie rod assembly to the relay rod.
(d) Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)

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Alignment
Marks SR−88
− STEERINGSTEERING LINKAGE
1996 TOYOTA T100 (RM449U)
5. INSTALL PITMAN ARM
(a) Align the alignment marks on the pitman arm and the
cross shaft.
(b) Install the spring washer and pitman arm set nut.
Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
(c) Connect the pitman arm to the relay rod.
(d) Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
6. INSTALL ENGINE UNDER COVER
Tighten the 4 bolts.
7. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)

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Idler Arm Bracket Cap
Plate Washer
Idler Arm Bracket
Non−reusable part
Molybdenum disulfide lithium base greaseIdler Arm  Bushing
 Oil Seal


78 (800, 58)
: Specified torque
N·m (kgf·cm, ft·lbf)
SR089−02
− STEERINGIDLER ARM
SR−89
1763 Author: Date:
1996 TOYOTA T100 (RM449U)
IDLER ARM
COMPONENTS

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SR−90
− STEERINGIDLER ARM
1996 TOYOTA T100 (RM449U)
REMOVAL
(See page SR−85)

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SR1279
SR1287
R04472
− STEERINGIDLER ARM
SR−91
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE IDLER ARM BRACKET CAP
Using a screwdriver and a hammer, remove the idler arm brack-
et cap.
NOTICE:
Be careful not to damage the idler arm bracket.
2. MEASURE IDLER ARM ROTATING TORQUE
(a) Check that the arm rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the arm rotating torque.
Rotating torque:
0.5 − 2.9 N·m (5 − 30 kgf·cm, 5 − 26 in.·lbf)
3. REMOVE IDLER ARM
Remove the nut and plate washer, and pull the idler arm off the
idler arm bracket.
4. REMOVE OIL SEAL
5. REMOVE 2 BUSHINGS
Using a screwdriver, remove the bushing.
NOTICE:
Be careful not to damage the idler arm bracket.

Downloaded from www.Manualslib.com manuals search engine SR08C−01
R14326
SST
R04473
SR1285
SST SR−92
− STEERINGIDLER ARM
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM
BASE GREASE
(See page SR−89)
2. INSTALL 2 BUSHINGS
Using SST and a hammer, tap in a new bushing to the idler arm
braket.
SST 09950−60010 (09951−00300),
09950−70010 (09951−07200)
3. INSTALL OIL SEAL
(a) Coat a new oil seal lip with molybdenum disulfide lithium
base grease.
(b) Install the oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.
4. INSTALL IDLER ARM
(a) Install the idler arm to the bracket.
(b) Install the plate washer and nut.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
5. MEASURE IDLER ARM ROTATING TORQUE
(See page SR−91)
6. INSTALL IDLER ARM BRACKET CAP
(a) Apply sealant to a new cap end.
Sealant: Part No.08826−00090, THREE BOND 1281 or
equivalent
(b) Using SST, tap in the idler arm bracket cap.
SST 09223−46011

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− STEERINGIDLER ARM
SR−93
1996 TOYOTA T100 (RM449U)
INSTALLATION
(See page SR−87)