light TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine R12236
A
− BRAKEBRAKE MASTER CYLINDER
BR−13
1996 TOYOTA T100 (RM449U)
(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No.2 piston drops out of cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).

Downloaded from www.Manualslib.com manuals search engine BR2237
BR08Z−01
BR2238
GOOD NO GOOD
1st2nd3rd
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−17
1622 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE BOOSTER ASSEMBLY
ON−VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off,
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down furthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop it with the pedal depressed. If there is no change in
pedal reserve travel after holding the pedal for 30 se-
conds, the booster is air tight.

Downloaded from www.Manualslib.com manuals search engine BR092−01
BR3286
F03521
SST
Gasket
Z03607
SST BR−20
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install a new gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737−00010
(c) Turn the SST upside down, and set it on the booster.
SST 09737−00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod light-
ly touches the pin head.
3. INSTALL MASTER CYLINDER (See page BR−16)
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR−4)
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL
(See page BR−6)
Check and adjust the brake pedal, then tighten the clevis lock
nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
8. DO OPERATIONAL CHECK (See page BR−17)

Downloaded from www.Manualslib.com manuals search engine BR09Q−01
BR0122
C
A
BAdjusting Bolt
BR0973
Z03640
Z03659
− BRAKEREAR DRUM BRAKE (4WD)
BR−49
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR−45).
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR−44).
1. ADJUST BELLCRANK
(a) Lightly pull the bellcrank in direction A until there is no
slack at part B.
(b) In this condition, turn the adjusting bolt so that dimension
C will be 0.4 − 0.8 mm (0.016 − 0.031 in.).
(c) Lock the adjusting bolt with the lock nut.
(d) Connect the parking brake cable to the parking brake bell-
crank and install the clip.
(e) Install the tension spring.
2. CHECK OPERATION OF AUTOMATIC ADJUSTING
MECHANISM
(a) Move the parking brake lever of the front shoe back and
forth. Check that the adjuster turns.
If the adjuster does not turn, check for incorrect installation of
the rear brakes.
(b) Adjust the adjuster length as short as possible.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM (See page BR−43)
Shoe clearance: 0.6 mm (0.024 in.)
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See Page BR−4)
5. CHECK FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine BR09X−01
Z11332
SST
Z11333
A
BR0218
BR0061
SST
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)BR−57
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL LSP & BV ASSEMBLY TO FRAME
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
2. CONNECT BRAKE LINE
Using SST, connect the brake lines.
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
SST 09751−36011
3. CONNECT SHACKLE NO.2 BRACKET
(a) Install the shackle No.2 to the load sensing spring.
(b) Set dimension A and torque the lock nut.
Initial set: 120 mm (4.72 in.)
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Connect the shackle No.2 to the shackle bracket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install a new cotter pin.
4. SET REAR AXLE LOAD
(See page BR−50)
5. SET VALVE BODY
(a) When pulling down the load sensing spring, check that
the valve piston moves down smoothly.
(b) Position the valve body so that the valve piston lightly
contacts with the load sensing spring.
(c) Tighten the valve body mounting nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. BLEED BRAKE LINE (See page BR−4)
7. CHECK AND ADJUST LSP & BV FLUID PRESSURE
(See page BR−50)
8. APPLY SEALANT TO SHACKLE No.2
Apply sealant to the top portion of the shackle No.2 bolt threads
not to lose the upper lock nut.
Sealant:
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent

Downloaded from www.Manualslib.com manuals search engine R07653
SR0097
SR075−01
R09732
− STEERINGSTEERING WHEEL
SR−9
1683 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING WHEEL
INSPECTION
1. CHECK THAT STEERING WHEEL FREEPLAY IS COR-
RECT
With the vehicle stopped and tires pointed straight ahead, rock
the steering wheel gently back and forth with light finger pres-
sure.
Freeplay should not exceed the maximum.
Maimum freeplay: 30 mm (1.18 in.)
4WD:
If the freeplay exceeds the maximum, adjust it in the following
procedure.
2. 4WD:
ADJUST STEERING GEAR
(a) Point the front wheels straight ahead.
(b) Loosen the adjusting screw lock nut.
(c) Turn the sector shaft adjusting screw clockwise to de-
crease steering wheel freeplay and counterclockwise to
increase it.
HINT:
Turn the adjusting screw in small increments and check the
freeplay between each adjustment.
(d) Turn the steering wheel half way around in both direc-
tions.
Check the the freeplay is correct and steering is smooth
and without rough spots.
(e) Torque the adjusting screw lock nut (See page SR−80).
3. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b) Remove the steering wheel pad (See page SR−13).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Reference: 8.3 N·m (85 kgf·cm, 73 in.·lbf)
HINT:
Be sure to consider the tire type, pressure and contact surface
before making your diagnosis.
(e) Torque the steering wheel set nut.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
(f) Install the steering wheel pad (See page SR−20).

Downloaded from www.Manualslib.com manuals search engine W03127
AT:
For 2WDParking Lock Cable
Steering Wheel
Steering Wheel Torx Screw
Steering Wheel Lower
No.2 CoverPad Control Shaft Column Upper
Cover
Lever
 Locking
Wire
Column Hole
CoverSteering Column Assembly
Steering Wheel Lower
No.3 Cover
Torx Screw
Combination Switch
(w/ Spiral Cable)
Column Lower Cover
Light Control Rheostat
Front Door Scuff
Plate Sliding w/ Shaft York
Sub−Assembly
Lower Finish Panel No.1
Intermediate
Shaft Assembly
Engine Hood Release
Lever
Duct Heater to
Register No.2
Intermediate
Shaft Assembly
Cowl Side Trim
 Non−reusable partControl Shaft Assembly
x35 (360, 26)
25 (260, 19)
35 (360, 26)
35 (360, 26)
35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
9.0 (90, 78 in.·lbf)
9.0 (90, 78 in.·lbf)
SR076−01
SR−10
− STEERINGNON−TILT STEERING COLUMN
1684 Author: Date:
1996 TOYOTA T100 (RM449U)
NON−TILT STEERING COLUMN
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine W03128
MT:
Column Upper
Cover
Torx Screw
Steering Wheel
Pad
Steering Wheel
Steering Wheel Lower
No.3 Cover
Torx Screw
Combination Switch
(w/ Spiral Cable)
Column Lower Cover
Light Control Rheostat
Front Door Scuff
Plate Steering Wheel Lower
No.2 Cover
Steering Column Assembly
Column Hole Cover
x7
Engine Hood Release
LeverLower Finish Panel No.1Sliding w/ Shaft York
Sub−Assembly
Intermediate
Shaft Assembly
Duct Heater to
Register No.2
Cowl Side Trim Intermediate
Shaft Assembly For 2WD9.0 (90, 78 in.·lbf)35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
9.0 (90, 78 in.·lbf)
25 (260, 19)
35 (360, 26)
35 (360, 26)
35 (360, 26)
− STEERINGNON−TILT STEERING COLUMN
SR−11
1685 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine Q02574
Matchmarks
Cap Nut SR−14
− STEERINGNON−TILT STEERING COLUMN
1996 TOYOTA T100 (RM449U)
3. A/T:
REMOVE UPPER AND LOWER COLUMN COVERS
Remove the 6 screws.
4. M/T:
REMOVE UPPER AND LOWER COLUMN COVERS
Remove the 7 screws.
5. REMOVE LOWER FINISH PANEL NO.1
(a) Remove the 2 screws and disconnect the engine hood re-
lease lever from the panel.
(b) Remove the 4 screws and front door scuff plate.
(c) Remove the clip and cowl side trim.
(d) Remove the 4 panel set bolts.
(e) Remove the light control rheostat and lock nut.
6. REMOVE DUCT HEATER TO REGISTER NO.2
Remove the screw.
7. REMOVE COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Remove the 2 screws.
(b) Disconnect the connectors.
(c) Disconnect the airbag connector.
(d) Remove the 4 screws.
8. REMOVE SPIRAL CABLE
(See page BE−15)
NOTICE:
Do not disassemble the cable or apply oil to it.
9. A/T:
DISCONNECT PARKING LOCK CABLE
(a) Place the matchmarks on the cap nut and parking lock
cable.
(b) Loosen the cap nut.
(c) Disconnect the parking lock cable.

Downloaded from www.Manualslib.com manuals search engine R07644Red Mark
R07660
Torx ScrewScrew Case
− STEERINGNON−TILT STEERING COLUMN
SR−21
1996 TOYOTA T100 (RM449U)
9. INSTALL COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Install the 4 screws.
(b) Connect the airbag connector.
(c) Connect the connectors.
(d) Install the 2 screws.
10. INSTALL DUCT HEATER TO REGISTER NO.2
Install the screw.
11. INSTALL LOWER FINISH PANEL NO.1
(a) Install the lock nuts and light control rheostat.
(b) Tighten the 4 panel set bolts.
(c) Install the cowl side trim and clip.
(d) Install the front door scuff plate with the 4 screws.
(e) Install the engine hood release lever with the 2 screws.
12. A/T:
INSTALL UPPER AND LOWER COLUMN COVERS
Install the 6 screws.
13. M/T:
INSTALL UPPER AND LOWER COLUMN COVERS
Install the 7 screws.
14. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the spiral counterclockwise by hand until it becomes
harder to turn the cable.
(c) Then turn the spiral cable clockwise about 3 turns to align
the red mark.
HINT:
The spiral cable turns clockwise about 3 turns to either left or
right of the center.
15. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and main shaft.
(b) Torque the set nut.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
(c) Connect the connector.
16. INSTALL STEERING WHEEL PAD
NOTICE:
Make sure the wheel pad is installed to the specified
torque.
If the wheel pad has been dropped, or there are
cracks, dents in the case or connector, replace the
wheel pad with a new one.
When installing the wheel pad, take care that the wir-
ings do not interfere with other parts and are not
pinched between other parts.