TOYOTA T100 1996 Factory Service Manual

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− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
SS−51
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Valve body x Transmission case101007
Oil strainer x Valve body (A340E)5.45548 in.·lbf
Oil strainer case x Valve body (A340F)101007
Oil strainer x Valve body (A340F)6.97061 in.·lbf
Oil pan7.47565 in.·lbf
Drain plug2020515
Parking lock pawl bracket x Transmission case7.47565 in.·lbf
Extension housing x Transmission case (A340E)3637027
Extension housing x Rear mounting insulator2525018
Rear support member x Rear mounting insulator (A340F)1818013
Rear support member x Body (A340F)9597070
Rear mounting insulator x Rear mounting bracket (A340E)1818013
Rear mounting bracket x Frame (A340E)5859042
Propeller shaft x Rear differential (A340E)7475054
Front propeller shaft x Front differential (A340F)7475054
Front propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Rear differential (A340F)7475054
Center support bearing x Body3637027
Drive plate x Crankshaft8385061
Torque converter clutch x Drive plate4142030
Stiffener plate x Engine (A340F)3738027
Stiffener plate x Transmission3738027
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x TWC4849035
Rear support member x Dynamic damper6162044
Oil cooler pipe3435025
Transmission x Engine7173053
Rear end plate x Transmission3738027
Rear support member x Transfer under cover2930021
Cross shaft x Frame2829021
Cross shaft x Transmission131309
Cross shaft x No.1 gear shifting rod131309
Exhaust pipe clamp(3RZ−FE)1919514
Exhaust pipe support bracket x Transmission (3RZ−FE)7173053
Exhaust pipe support bracket x Transmission (5VZ−FE)4445033
Exhaust pipe support bracket x Exhaust pipe (5VZ−FE)4445033
Park/neutral position switch (Nut)3.94035 in.·lbf
Park/neutral position switch (Bolt)131309
No.2 vehicle speed sensor5.45548 in.·lbf
Speedometer driven gear sleeve x Locking plate1616012
ATF temperature sensor x Transmission1515011
Shift lever assembly x Steering column assembly2930022

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− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U) Shift lever sub−assembly x Control shaft assembly
1919514
Casing cap x Control shaft support sub−assembly5051037

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− SERVICE SPECIFICATIONSTRANSFER
SS−53
227 Author: Date:
1996 TOYOTA T100 (RM449U)
TRANSFER
SERVICE DATA
Oil pump body
Body clearance STD
Maximum
Tip clearance STD
Maximum
Side clearance STD
Maximum
0.10 − 0.16 mm (0.0039 − 0.0063 in.)
0.16 mm (0.0063 in.)
0.08 − 0.15 mm (0.0031 − 0.0059 in.)
0.16 mm (0.0063 in.)
0.03 − 0.08 mm (0.0012 − 0.0031 in.)
0.08 mm (0.0031 in.)
Rear output shaft assembly
Drive sprocket thrust clearance STD
Maximum
Rear output shaft journal diameter
(part A)Minimum
(part B)Minimum
Drive sprocket radial clearance STD
Maximum
Front drive shift fork to hub sleeve clearanceMaximum
High and low shift fork to hub sleeve clearanceMaximum
Rear output shaft snap ring thicknessMark
A
B
C
D
E
F
G
H
J
K
L
0.10 − 0.25 mm (0.0039 − 0.0098 in.)
0.25 mm (0.0098 in.)
27.98 mm (1.1016 in.)
36.99 mm (1.4563 in.)
0.010 − 0.055 mm (0.0004 − 0.0022 in.)
0.055 mm (0.0022 in.)
1.0 mm (0.039 in.)
1.0 mm (0.039 in.)
2.10 − 2.15 mm (0.0827 − 0.0846 in.)
2.15 − 2.20 mm (0.0846 − 0.0866 in.)
2.20 − 2.25 mm (0.0866 − 0.0886 in.)
2.25 − 2.30 mm (0.0886 − 0.0906 in.)
2.30 − 2.35 mm (0.0906 − 0.0925 in.)
2.35 − 2.40 mm (0.0925 − 0.0945 in.)
2.40 − 2.45 mm (0.0945 − 0.0965 in.)
2.45 − 2.50 mm (0.0965 − 0.0984 in.)
2.50 − 2.55 mm (0.0984 − 0.1004 in.)
2.00 − 2.05 mm (0.0787 − 0.0807 in.)
2.05 − 2.10 mm (0.0807 − 0.0827 in.)
Input shaft
Input shaft journal outer diameterMinimum
Input shaft bushing diameterMaximum
Synchronizer ring to sprocket clearance STD
Minimum
Input shaft snap ring thicknessMark
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
U
47.59 mm (1.8736 in.)
39.14 mm (1.5409 in.)
1.15 − 1.85 mm (0.0453 − 0.0728 in.)
0.80 mm (0.0315 in.)
2.10 − 2.15 mm (0.0827 − 0.0846 in.)
2.15 − 2.20 mm (0.0846 − 0.0866 in.)
2.20 − 2.25 mm (0.0866 − 0.0886 in.)
2.25 − 2.30 mm (0.0886 − 0.0906 in.)
2.30 − 2.35 mm (0.0906 − 0.0925 in.)
2.35 − 2.40 mm (0.0925 − 0.0945 in.)
2.40 − 2.45 mm (0.0945 − 0.0965 in.)
2.45 − 2.50 mm (0.0965 − 0.0984 in.)
2.50 − 2.55 mm (0.0984 − 0.1004 in.)
2.55 − 2.60 mm (0.1004 − 0.1024 in.)
2.60 − 2.65 mm (0.1024 − 0.1043 in.)
2.65 − 2.70 mm (0.1043 − 0.1063 in.)
2.70 − 2.75 mm (0.1063 − 0.1083 in.)
2.75 − 2.80 mm (0.1083 − 0.1102 in.)
2.80 − 2.85 mm (0.1102 − 0.1122 in.)
2.85 − 2.90 mm (0.1122 − 0.1142 in.)
2.90 − 2.95 mm (0.1142 − 0.1161 in.)
2.95 − 3.00 mm (0.1161 − 0.1181 in.)
3.00 − 3.05 mm (0.1181 − 0.1201 in.)

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− SERVICE SPECIFICATIONSTRANSFER
228 Author: Date:
1996 TOYOTA T100 (RM449U) Planetary gear
Pinion gear thrust clearance STD
Maximum
Pinion gear radial clearance STD
Maximum
Outer bearing snap ring thicknessMark
1
2
3
4
5
Inner bearing depth
0.11 − 0.86 mm (0.0043 − 0.0339 in.)
0.86 mm (0.0339 in.)
0.009 − 0.038 mm (0.0004 − 0.0015 in.)
0.038 mm (0.0015 in.)
1.45 − 1.50 mm (0.0571 − 0.0591 in.)
1.50 − 1.55 mm (0.0591 − 0.0610 in.)
1.55 − 1.60 mm (0.0610 − 0.0630 in.)
1.60 − 1.65 mm (0.0630 − 0.0650 in.)
1.65 − 1.70 mm (0.0650 − 0.0669 in.)
5.0 − 5.6 mm (0.197 − 0.220 in.)
Oil seal
Shift fork shaft oil seal depth
Speedometer driven gear oil seal depth
−0.5 − 0.5 mm (−0.020 − 0.020 in.)
25 mm (0.98 in.)

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− SERVICE SPECIFICATIONSTRANSFER
SS−55
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transfer x Dynamic damper3738027
Transfer adaptor x Transfer3738027
Engine rear mounting2526019
Indicator switch3738027
L4 position switch3738027
Transfer assembly x Transmission3738027
Front retainer1111 58
Control retainer or upper cover1818513
Companion flange lock nut11 81,20087
Extension housing1111 58
Front case x Rear case3738027
Straight screw plug for shift fork shaft1919014
Separator with oil strainer1818513
Oil pump body x Front case1111 58
Straight screw plug for ring gear1919014
Straight screw plug for oil pump body2930021
Oil pump plate x Oil pump body7.47565 in.·lbf

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SS−56
− SERVICE SPECIFICATIONSPROPELLER SHAFT
230 Author: Date:
1996 TOYOTA T100 (RM449U)
PROPELLER SHAFT
SERVICE DATA
Propeller shaft runoutMaximum runout0.8 mm (0.031 in.)
Spider bearing axial play0.05 mm (0.0020 in.)
Snap ring thickness 2WD (TMC−made) and 4WD Mark Color
1 −2.100 − 2.150 mm (0.0827 − 0.0846 in.)
2 −2.150 − 2.200 mm (0.0846 − 0.0866 in.)
3 −2.200 − 2.250 mm (0.0866 − 0.0886 in.)
− Brown2.250 − 2.300 mm (0.0886 − 0.0906 in.)
− Bule2.300 − 2.350 mm (0.0906 − 0.0925 in.)
6 −2.350 − 2.400 mm (0.0925 − 0.0945 in.)
7 −2.400 − 2.450 mm (0.0945 − 0.0965 in.)
8 −2.450 − 2.500 mm (0.0965 − 0.0984 in.)
Snap ring thickness 2WD (DANA−made) Color
Green1.384 mm (0.0545 in.)
Red1.435 mm (0.0565 in.)
Black1.486 mm (0.0585 in.)
Copper1.511 mm (0.0895 in.)
Silver1.537 mm (0.0605 in.)
Yellow1.588 mm (0.0625 in.)
Blue1.638 mm (0.0645 in.)

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− SERVICE SPECIFICATIONSPROPELLER SHAFT
SS−57
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Propeller shaft x Differential 2WD7475054
Intermediate shaft x Propeller shaft 2WD7475054
Front propeller shaft x Front differential 4WD7475054
Front propeller shaft x Transfer 4WD7475054
Rear propeller shaft x Rear differential 4WD7678056
Rear propeller shaft x Transfer 4WD7678056
Intermediate shaft x Propeller shaft 4WD7678056
Center support bearing x Body3637027
Intermediate shaft x Center support bearing x Joint flange
1st1811,850134
Loosen nut
2WD (TMC−made) and 4WD 2nd6970051
2WD (DANA−made) 2nd8183060
Front propeller shaft No.2 dust cover set bolts1717513
Front propeller shaft No.2 dust cover set nuts1313510
Front propeller shaft dust cover bracket x Bracket2323017
Front propeller shaft dust cover bracket x Transfer3637027

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SS−58
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
232 Author: Date:
1996 TOYOTA T100 (RM449U)
SUSPENSION AND AXLE
SERVICE DATA
Cold tire inflation
pressure (2WD)
P215/75R15Front 230 kPa (2.3 kgf/cm2,
33 psi)
Rear 240 kPa (2.4 kgf/cm2, 35 psi)
P235/75R15 (0.5 ton)Front 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 200 kPa (2.0 kgf/cm2, 29 psi)
P235/75R15 (1.0 ton)Front 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 280 kPa (2.8 kgf/cm2, 41 psi)
Cold tire inflation
pressure (4WD)
P235/75R15STD cabFront 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 200 kPa (2.0 kgf/cm2, 29 psi)31x10.5R15LTSTD cab
P235/75R15Extra cabFront 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 240 kPa (2.4 kgf/cm2, 35 psi)
31x10.5R15LTExtra cabFront 200 kPa (2.0 kgf/cm2, 29 psi)
Rear 240 kPa (2.4 kgf/cm2, 35 psi)
Wheel alignment
(Standard loaded
vehicle condition)
(2WD)
Vehicle height STD cab 0.5 ton
STD cab 1.0 ton
Extra cabFront *174.0 mm (2.913 in.)
Rear *2122.0 mm (4.803 in.)
Front *174.0 mm (2.913 in.)
Rear *2107.0 mm (4.213 in.)
Front *174.0 mm (2.913 in.)
Rear *2115.5 mm (4.547 in.)
Camber
Left−right error0°00’ ± 45’ (0° ± 0.75°)
45’ (0.75°) or less
Caster
Left−right error4°00’ ± 45’ (4° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error12°30’ ± 45’ (12.5° ± 0.75°)
45’ (0.75°) or less
To e−in (Total)STD cab
Extra cab (P215/75R15)
Extra cab (P235/75R15)
Rack end length difference0° ± 12’ (0° ± 0.2°, 0 ± 2 mm, 0 ± 0.08 in.)
−0°22’ ± 12’ (−0.36° ± 0.2°, 4.7 ± 2 mm, −0.18 ± 0.08 in.)
−0°22’ ± 12’ (−0.36° ± 0.2°, 4.9 ± 2 mm, −0.19 ± 0.08 in.)
3.0 mm (0.118 in.) or less
Wheel angle
STD cab 0.5 ton Inside wheel
Outside wheel
STD cab 1.0 ton Inside wheel
Outside wheel
Extra cab Inside wheel
Outside wheel
Left−right error
40°42’ ± 2° (40.7° ± 2°)
34°23’ (34.38°)
39°55’ ± 2° (39.92° ± 2°)
34°37’ (34.62°)
40°10’ ± 2° (40.17° ± 2°)
34°25’ (34.42°)
30’ (0.5°) or less
*1: A − B
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
*
2: C − D
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.

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SS−59
233 Author: Date:
1996 TOYOTA T100 (RM449U) Wheel alignment
(Non−loaded
vehicle condition)
(2WD)
Vehicle height
RCK10L−TRMRKA P215/75R15
Front*145.4 mm (1.787 in.)
Rear*262.5 mm (2.460 in.)
RCK10L−TRMRKA P235/75R15Front*145.4 mm (1.787 in.)
Rear*261.4 mm (2.417 in.)
RCK10L−TRSRKA P215/75R15Front*145.4 mm (1.787 in.)
Rear*263.5 mm (2.500 in.)
VCK11L−TRMDKA P215/75R15Front*148.0 mm (1.890 in.)
Rear*262.2 mm (2.449 in.)
VCK11L−TRMDKA P235/75R15Front*148.0 mm (1.890 in.)
Rear*263.3 mm (2.492 in.)
VCK11L−THMDKA 5VZ−FE Engine (1.0 ton)Front*149.4 mm (1.945 in.)
Rear*232.3 mm (1.272 in.)
VCK11L−TRSDKA P215/75R15Front*149.9 mm (1.965 in.)
Rear*263.5 mm (2.500 in.)
VCK11L−TRSDKA P235/75R15Front*149.9 mm (1.965 in.)
Rear*264.6 mm (2.543 in.)
VCK11L−THSDKA 5VZ−FE Engine (1.0 ton)Front*149.9 mm (1.965 in.)
Rear*233.0 mm (1.299 in.)
VCK11L−CRMDKA P215/75R15Front*138.8 mm (1.528 in.)
Rear*245.6 mm (1.795 in.)
VCK11L−CRMSKA P235/75R15Front*138.8 mm (1.528 in.)
Rear*245.8 mm (1.803 in.)
VCK11L−CRSDKA P215/75R15Front*138.8 mm (1.528 in.)
Rear*246.6 mm (1.835 in.)
VCK11L−CRSDKA P235/75R15Front*138.8 mm (1.528 in.)
Rear*245.5 mm (1.791 in.)
VCK11L−CRSSKA P235/75R15Front*138.8 mm (1.528 in.)
Rear*246.7 mm (1.839 in.)
VCK11L−CRMDKA P235/75R15Front*138.8 mm (1.528 in.)
Rear*244.6 mm (1.756 in.)
*1: A − B
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
*
2: C − D
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.

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− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
234 Author: Date:
1996 TOYOTA T100 (RM449U) Wheel alignment
(Non−loaded
vehicle condition)
(2WD)
Camber
STD cab 3RZ−FE, 5VZ−FE engine (0.5 ton)
STD cab 5VZ−FE engine (1.0 ton)
Extra cab
Left−right error
0°24’ ± 45’ (0.4° ± 0.75°)
0°22’ ± 45’ (0.37° ± 0.75°)
0°28’ ± 45’ (0.47° ± 0.75°)
45’ (0.75°) or less
Caster
STD cab 3RZ−FE, 5VZ−FE engine (0.5 ton)
STD cab 5VZ−FE engine 1.0 ton
Extra cab
Left−right error
2°28’ ± 45’ (2.47° ± 0.75°)
1°38’ ± 45’ (1.63° ± 0.75°)
2°04’ ± 45’ (2.06° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination STD cab 0.5 ton
STD cab 1.0 ton
Extra cab
Left−right error12°05’ ± 45’ (12.08° ± 0.75°)
12°10’ ± 45’ (12.17° ± 0.75°)
12°00’ ± 45’ (12° ± 0.75°)
45’ (0.75°) or less
To e−in (Total)
STD cab 3RZ−FE, 5VZ−FE engine (0.5 ton)
STD cab 5VZ−FE engine (1.0 ton)
Extra cab
Rack end length difference
0°11’ ± 12’ (0.19° ± 0.2°, 2.4 ± 2 mm, 0.09 ± 0.08 in.)
0°33’ ± 12’ (0.55° ± 0.2°, 7.0 ± 2 mm, 0.28 ± 0.08 in.)
0°20’ ± 12’ (0.33° ± 0.2°, 6.1 ± 2 mm, 0.24 ± 0.08 in.)
3.0 mm (0.118 in.) or less
Wheel angle
STD cab 3RZ−FE, 5VZ−FE engine (0.5 ton)
Inside wheel
Outside wheel
STD cab 5VZ−FE engine (1.0 ton) Inside wheel
Outside wheel
Extra cab Inside wheel
Outside wheel
Left−right error
40°42’ ± 2° (40.7° ± 2°)
35°07’ (35.12°)
40°23’ ± 2° (40.38° ± 2°)
35°31’ (35.52°)
40°50’ ± 2° (40.83° ± 2°)
35°41’ (35.68°)
30’ (0.5°) or less