TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS−61
235 Author: Date:
1996 TOYOTA T100 (RM449U) Wheel alignment
(Standard loaded
vehicle condition)
(4WD)
Vehicle height STD cab
Extra cabFront *158.0 mm (2.283 in.)
Rear *223.0 mm (0.906 in.)
Front *158.0 mm (2.283 in.)
Rear *228.0 mm (1.102 in.)
Camber
Left−right error0°45’ ± 45’ (0.75° ± 0.75°)
45’ (0.75°) or less
Caster STD cab
Extra cab
Left−right error1°30’ ± 45’ (1.5° ± 0.75°)
1°20’ ± 45’ (1.33° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error11°50’ ± 45’ (11.83° ± 0.75°)
45’ (0.75°) or less
To e−in (Total)STD cab
Extra cab (P235/75R15)
Extra cab (31x10.5R15)
Rack end length difference0°05’ ± 12’ (0.08° ± 0.2°, 1.0 ± 2 mm, 0.04 ± 0.08 in.)
−0°08’ ± 12’ (−0.14° ± 0.2°, 1.9 ± 2 mm, −0.07 ± 0.08 in.)
−0°08’ ± 12’ (−0.14° ± 0.2°, 2.0 ± 2 mm, −0.08 ± 0.08 in.)
3.0 mm (0.118 in.) or less
Wheel angle
STD cab Inside wheel
Outside wheel
Extra cab Inside wheel
Outside wheel
Left−right error
32°01’ ± 2° (32.02° ± 2°)
30°12’ (30.2°)
32°14’ ± 2° (32.23° ± 2°)
29°59’ (29.99°)
30’ (0.5°) or less
Wheel alignment
(Non−loaded
vehicle condition)
(4WD)
Vehicle height
VCK21L−TRMDKA P235/75R15
Front*138.3 mm (1.508 in.)
Rear*270.7 mm (2.783 in.)
VCK21L−TRMDKA 31x10.5R15Front*138.3 mm (1.508 in.)
Rear*272.6 mm (2.858 in.)
VCK21L−TRSDKA P235/75R15Front*140.0 mm (1.575 in.)
Rear*269.5 mm (2.736 in.)
VCK21L−TRSDKA 31x10.5R15Front*140.0 mm (1.575 in.)
Rear*271.4 mm (2.811 in.)
VCK21L−CRM#KA P235/75R15Front*132.3 mm (1.272 in.)
Rear*277.2 mm (3.039 in.)
VCK21L−CRM#KA 31x10.5R15Front*132.3 mm (1.272 in.)
Rear*279.4 mm (3.126 in.)
VCK21L−CRS#KA P235/75R15Front*132.3 mm (1.272 in.)
Rear*276.2 mm (3.000 in.)
VCK21L−CRS#KA 31x10.5R15Front*132.3 mm (1.272 in.)
Rear*278.3 mm (3.083 in.)
#: Any letter is applicable.
*
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 leaf spring front bushing center.
D: Ground clearance of rear axle shaft center.

Downloaded from www.Manualslib.com manuals search engine SS−62
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
236 Author: Date:
1996 TOYOTA T100 (RM449U) Wheel alignment
(Non−loaded
vehicle condition)
(4WD)
Camber STD cab
Extra cab
Left−right error0°35’ ± 45’ (0.59° ± 0.75°)
0°40’ ± 45’ (0.66° ± 0.75°)
45’ (0.75°) or less
Caster STD cab
Extra cab
Left−right error0°59’ ± 45’ (0.98° ± 0.75°)
1°10’ ± 45’ (1.17° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error12°00’ ± 45’ (12° ± 0.75°)
45’ (0.75°) or less
To e−in (Total)STD cab
Extra cab (P235/75R15)
Extra cab (31x10.5R15)0°12’ ± 12’ (0.2° ± 0.2°, 2.7 ± 2 mm, 0.11 ± 0.08 in.)
0°08’ ± 12’ (0.14° ± 0.2°, 1.9 ± 2 mm, 0.07 ± 0.08 in.)
0°08’ ± 12’ (0.14° ± 0.2°, 2.0 ± 2 mm, 0.08 ± 0.08 in.)
Wheel angle
STD cab Inside wheel
Outside wheel
Extra cab Inside wheel
Outside wheel
32°45’ ± 2° (32.75° ± 2°)
30°31’ (30.52°)
33°07’ ± 2° (33.12° ± 2°)
30°31’ (30.52°)
Front axle (2WD)
Axle hub axial playMaximum0.05 mm (0.0020 in.)
Axle hub preload (at starting)Friction force plus
5.0 − 14.0 N (0.5 − 1.4 kgf, 1.1 − 3.1 in.)
Front axle (4WD)Axle hub preload (at starting)25 − 53 N (2.6 − 5.4 kgf, 5.7 − 11.9 lbf)
Front drive shaft thrust clearanceStandard0.1 − 0.5 mm (0.0039 − 0.0197 in.)
Front drive shaft
(4WD)Drive shaft length481.2 − 491.2 mm (18.945 − 19.339 in.)
Front suspension
(2WD)Upper ball joint turning torque2.0 − 3.9 N·m (20 − 40 kgf·cm, 17 − 34 in.·lbf)
Lower ball joint turning torque2.0 − 7.0 N·m (20 − 70 kgf·cm, 17 − 61 in.·lbf)
Front suspension
(4WD)Upper ball joint turning torque0.5 − 2.4 N·m (5 − 25 kgf·cm, 4 − 22 in.·lbf)
Lower ball joint turning torque2.0 − 3.9 N·m (20 − 40 kgf·cm, 17 − 34 in.·lbf)
Rear axleShaft runoutMaximum2.0 mm (0.079 in.)
Flange runoutMaximum0.1 mm (0.004 in.)
Front differential
(4WD)
Companion flange vertical runoutMaximum0.10 mm (0.0039 in.)
Companion flange lateral runout Maximum0.10 mm (0.0039 in.)
Drive pinion bearing preload (at starting)
New bearing
Reused bearing
1.2 − 1.9 N·m (12 − 19 kgf·cm, 10.4 − 16.5 in.·lbf)
0.6 − 1.0 N·m (6 − 10 kgf·cm, 5.2 − 8.7 in.·lbf)
Total preload (at starting)In addition to drive pinion preload
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
Pinion gear to side gear backlash0.05 − 0.20 mm (0.0020 − 0.0079 in.)
Drive pinion to ring gear backlash0.13 − 0.18 mm (0.0051 − 0.0070 in.)
Ring gear runoutMaximum0.07 mm (0.0028 in.)
Rear oil seal drive in depth1.5 mm (0.059 in.)
Side gear shaft tube LH side oil seal drive in depth2.5 mm (0.098 in.)
A.D.D. sleeve fork to clutch sleeve clearance0.35 mm (0.0138 in.)
Differential bearing press in depth2.0 mm (0.079 in.)

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS−63
237 Author: Date:
1996 TOYOTA T100 (RM449U) Front differential
(4WD)
Side gear thrust washer thickness
0.96 − 1.04 mm (0.0378 − 0.0409 in.)
1.06 − 1.14 mm (0.0417 − 0.0449 in.)
1.16 − 1.24 mm (0.0457 − 0.0488 in.)
1.26 − 1.34 mm (0.0496 − 0.0528 in.)
Side gear bearing adjusting washer thickness
2.57 − 2.59 mm (0.1012 − 0.1020 in.)
2.60 − 2.62 mm (0.1024 − 0.1031 in.)
2.63 − 2.65 mm (0.1035 − 0.1043 in.)
2.66 − 2.68 mm (0.1047 − 0.1055 in.)
2.69 − 2.71 mm (0.1059 − 0.1067 in.)
2.72 − 2.74 mm (0.1071 − 0.1079 in.)
2.75 − 2.77 mm (0.1083 − 0.1091 in.)
2.78 − 2.80 mm (0.1094 − 0.1102 in.)
2.81 − 2.83 mm (0.1106 − 0.1114 in.)
2.84 − 2.86 mm (0.1118 − 0.1126 in.)
2.87 − 2.89 mm (0.1130 − 0.1138 in.)
2.90 − 2.92 mm (0.1142 − 0.1150 in.)
2.93 − 2.95 mm (0.1154 − 0.1161 in.)
2.96 − 2.98 mm (0.1165 − 0.1173 in.)
2.99 − 3.01 mm (0.1177 − 0.1185 in.)
3.02 − 3.04 mm (0.1189 − 0.1197 in.)
3.05 − 3.07 mm (0.1201 − 0.1209 in.)
3.08 − 3.10 mm (0.1213 − 0.1220 in.)
3.11 − 3.13 mm (0.1224 − 0.1232 in.)
3.14 − 3.16 mm (0.1236 − 0.1244 in.)
3.17 − 3.19 mm (0.1248 − 0.1256 in.)
3.20 − 3.22 mm (0.1260 − 0.1268 in.)
3.23 − 3.25 mm (0.1272 − 0.1280 in.)
Drive pinion bearing washer thickness
2.27 mm (0.0894 in.)
2.30 mm (0.0906 in.)
2.33 mm (0.0917 in.)
2.36 mm (0.0929 in.)
2.39 mm (0.0941 in.)
2.42 mm (0.0953 in.)
2.45 mm (0.0965 in.)
2.48 mm (0.0976 in.)
2.51 mm (0.0988 in.)
2.54 mm (0.1000 in.)
2.57 mm (0.1012 in.)
2.60 mm (0.1024 in.)
2.63 mm (0.1035 in.)
2.66 mm (0.1047 in.)
2.69 mm (0.1059 in.)

Downloaded from www.Manualslib.com manuals search engine SS−64
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
238 Author: Date:
1996 TOYOTA T100 (RM449U) Rear differential
Companion flange vertical runoutMaximum0.09 mm (0.0035 in.)
Companion flange lateral runout Maximum0.09 mm (0.0035 in.)
Drive pinion bearing preload (at starting)
New bearing
Reused bearing
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
Total preload (at starting)In addition to drive pinion preload
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
Pinion gear to side gear backlash0.05 − 0.20 mm (0.0020 − 0.0079 in.)
Drive pinion to ring gear backlash 2WD
4WD0.08 − 0.13 mm (0.0031 − 0.0051 in.)
0.13 − 0.18 mm (0.0051 − 0.0071 in.)
Ring gear runoutMaximum0.05 mm (0.0020 in.)
Differential case runoutMaximum0.04 mm (0.0016 in.)
Differential side gear thrust washer thickness
1.50 mm (0.0590 in.)
1.55 mm (0.0610 in.)
1.60 mm (0.0630 in.)
1.65 mm (0.0650 in.)
1.70 mm (0.0669 in.)
1.75 mm (0.0689 in.)
1.80 mm (0.0709 in.)
1.85 mm (0.0728 in.)
1.90 mm (0.0748 in.)
Side bearing adjusting washer thickness
58 2.58 mm (0.1015 in.)
60 2.60 mm (0.1024 in.)
62 2.62 mm (0.1031 in.)
64 2.64 mm (0.1039 in.)
66 2.66 mm (0.1047 in.)
68 2.68 mm (0.1055 in.)
70 2.70 mm (0.1063 in.)
72 2.72 mm (0.1071 in.)
74 2.74 mm (0.1079 in.)
76 2.76 mm (0.1087 in.)
78 2.78 mm (0.1094 in.)
80 2.80 mm (0.1102 in.)
82 2.82 mm (0.1110 in.)
84 2.84 mm (0.1118 in.)
86 2.86 mm (0.1126 in.)
88 2.88 mm (0.1134 in.)
90 2.90 mm (0.1142 in.)
92 2.92 mm (0.1150 in.)
94 2.94 mm (0.1157 in.)
96 2.96 mm (0.1165 in.)
98 2.98 mm (0.1173 in.)
00 3.00 mm (0.1181 in.)
02 3.02 mm (0.1189 in.)
04 3.04 mm (0.1197 in.)
06 3.06 mm (0.1205 in.)
08 3.08 mm (0.1213 in.)

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS−65
239 Author: Date:
1996 TOYOTA T100 (RM449U) Rear differential
Side bearing adjusting washer thickness
10 3.10 mm (0.1220 in.)
12 3.12 mm (0.1228 in.)
14 3.14 mm (0.1236 in.)
16 3.16 mm (0.1244 in.)
18 3.18 mm (0.1252 in.)
20 3.20 mm (0.1260 in.)
22 3.22 mm (0.1268 in.)
24 3.24 mm (0.1276 in.)
26 3.26 mm (0.1283 in.)
28 3.28 mm (0.1291 in.)
30 3.30 mm (0.1299 in.)
32 3.32 mm (0.1307 in.)
34 3.34 mm (0.1315 in.)
36 3.36 mm (0.1323 in.)
38 3.38 mm (0.1331 in.)
40 3.40 mm (0.1339 in.)
42 3.42 mm (0.1346 in.)
44 3.44 mm (0.1354 in.)
46 3.46 mm (0.1362 in.)
48 3.48 mm (0.1370 in.)
Drive pinion bearing adjusting washer thickness
87 1.87 mm (0.0736 in.)
88 1.88 mm (0.0740 in.)
89 1.89 mm (0.0744 in.)
90 1.90 mm (0.0748 in.)
91 1.91 mm (0.0752 in.)
92 1.92 mm (0.0756 in.)
93 1.93 mm (0.0760 in.)
94 1.94 mm (0.0764 in.)
95 1.95 mm (0.0768 in.)
96 1.96 mm (0.0772 in.)
97 1.97 mm (0.0776 in.)
98 1.98 mm (0.0780 in.)
99 1.99 mm (0.0783 in.)
00 2.00 mm (0.0787 in.)
01 2.01 mm (0.0791 in.)
02 2.02 mm (0.0795 in.)
03 2.03 mm (0.0799 in.)
04 2.04 mm (0.0803 in.)
05 2.05 mm (0.0807 in.)
06 2.06 mm (0.0811 in.)
07 2.07 mm (0.0815 in.)
08 2.08 mm (0.0819 in.)
09 2.09 mm (0.0823 in.)
10 2.10 mm (0.0827 in.)
11 2.11 mm (0.0831 in.)

Downloaded from www.Manualslib.com manuals search engine SS−66
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
240 Author: Date:
1996 TOYOTA T100 (RM449U) Rear differential
Drive pinion bearing adjusting washer thickness
12 2.12 mm (0.0835 in.)
13 2.13 mm (0.0839 in.)
14 2.14 mm (0.0843 in.)
15 2.15 mm (0.0846 in.)
16 2.16 mm (0.0850 in.)
17 2.17 mm (0.0854 in.)
18 2.18 mm (0.0858 in.)
19 2.19 mm (0.0862 in.)
20 2.20 mm (0.0866 in.)
21 2.21 mm (0.0870 in.)
22 2.22 mm (0.0874 in.)
23 2.23 mm (0.0878 in.)
24 2.24 mm (0.0882 in.)
25 2.25 mm (0.0886 in.)
26 2.26 mm (0.0890 in.)
27 2.27 mm (0.0894 in.)
28 2.28 mm (0.0898 in.)

Downloaded from www.Manualslib.com manuals search engine SS083−02
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS−67
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Front (2WD)
Tie rod end lock nut5657041
Steering knuckle x Upper ball joint1081,10080
Steering knuckle x Lower ball joint1421,450105
Steering knuckle x Brake caliper1081,10080
Steering knuckle x Steering knuckle arm1831,870135
Dust cover x Steering knuckle1919514
Disc x Axle hub6465047
Upper suspension arm x Upper ball joint3132023
Lower suspension arm x Lower ball joint7576055
Torque arm x Lower suspension arm4950036
Shock absorber x Frame2525018
Lower suspension arm x Shock absorber1818513
Lower suspension arm x Stabilizer bar131309
Lower suspension arm shaft nut2062,100152
Upper suspension arm shaft x Frame9698071
Upper suspension arm shaft x Upper suspension arm1261,28093
Lower ball joint x Strut bar7576055
Strut bar x Frame1231,25090
Stabilizer bar link set nut131309
Stabilizer bar bracket x Frame3030622
Hub nut1031,05076
ABS speed sensor x Steering knuckle8.08271 in.·lbf
ABS Speed sensor wire harness x Upper suspension arm5.05144 in.·lbf
Front (4WD)
Knuckle stopper bolt lock nut4748035
Tie rod clamp bolt2222516
Steering knuckle x Upper ball joint1421,450105
Steering knuckle x Lower ball joint5859043
Steering knuckle x Brake caliper1231,25090
Flange x Axle hub3131523
Flange x Front drive shaft1818513
Axle hub bearing lock nut4748035
Oil seal x Dust cover1818513
Upper suspension arm x Upper ball joint3334025
Lower suspension arm x Lower ball joint1421,450105
Steering knuckle arm x Steering knuckle1831,870135
Upper suspension arm x Torque arm8789064
Upper suspension arm shaft lock nut2262,300166
Shock absorber x Frame2525018
Lower suspension arm x Shock absorber1371,400101
Lower suspension arm x Stabilizer bar2526019
Stabilizer bar bracket x Frame2930022

Downloaded from www.Manualslib.com manuals search engine SS−68
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
1996 TOYOTA T100 (RM449U)Part tightened
N·mkgf·cmft·lbf
Front drive shaft x Side gear shaft8384561
Lower suspension arm x Frame1962,000145
Upper suspension arm shaft x Frame1781,810131
Hub nut1031,05076
ABS speed sensor x Steering knuckle8.08271 in.·lbf
ABS speed sensor wire harness5.05144 in.·lbf
Companion flange x Front differential assembly1081,10080
Drain plug4950036
Filler plug3940029
Crossmember x Frame1261,28093
Front mounting bolt1471,500108
Rear mounting bolt1671,700123
Actuator x Clutch case cover2121015
Screw plug x Clutch case cover2020014
A.D.D. indicator switch x Clutch case cover4041030
Carrier cover x Oil deflector7.47565 in.·lbf
Ring gear x Differential case9798571
Differential carrier x Bearing cap7880058
Clutch case x Tube7880058
Clutch case x Differential carrier78800500
Differential x Front propeller shaft7475054
Clutch case cover x Clutch case2121015
Differential carrier cover x Differential carrier4747534
Tube x Bearing retainer121209
Rear
Ring gear x Differential case1251,27092
Bearing cap x Differential carrier11 31,15083
Differential carrier x Axle housing7374054
Rear axle housing x Rear brake assembly6970051
Rear shock absorber x Spring seat2626019
Rear shock absorber x Frame2626019
U−bolt x Spring seat1321,35097
Shackle pin x Leaf spring9193067
Differential x Propeller shaft7678056
Hanger pin x Leaf spring9193067
Hanger pin lock bolt2626019
Leaf spring center bolt4445033
Hub nut1031,05076
Spring bumper seat set bolt2930022
ABS speed sensor x Rear axle housing8.08271 in.·lbf
Brake line1515511
Parking brake set bolt2526019
Drain plug4950036
Filler plug3940029

Downloaded from www.Manualslib.com manuals search engine SS084−01
− SERVICE SPECIFICATIONSBRAKE
SS−69
243 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE
SERVICE DATA
Brake pedal height (from asphalt sheet) Extra cab 4WD146.7−156.7 mm (5.776−6.169 in.)
Except extra cab 4WD149.7−159.7 mm (5.894−6.287 in.)
Brake pedal freeplay3−6 mm (0.12−0.24 in.)
Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf)
2WD 1 ton (STD cab)More than 78 mm (3.07 in.)
2WD 0.5 ton / 4WD (STD cab)More than 73 mm (2.87 in.)
4WD (Extra cab)More than 70 mm (2.76 in.)
Brake booster push rod to piston clearance (w/ SST)0 mm (0 in.)
Front brake pad thickness 2WD 1.0 ton STD9.5 mm (0.374 in.)
2WD 0.5 ton STD11.0 mm (0.433 in.)
4WD STD9.5 mm (0.374 in.)
Minimum1.0 mm (0.039 in.)
Disc thickness STD25.0 mm (0.984 in.)
Minimum23.0 mm (0.906 in.)
Disc runoutMaximum0.07 mm (0.0028 in.)
Rear brake drum inside diameter STD295.0 mm (11.614 in.)
Rear brake drum inside diameterMaximum297.0 mm (11.693 in.)
Rear brake shoe lining thickness STD6.0 mm (0.236 in.)
Rear brake shoe lining thicknessMinimum1.0 mm (0.039 in.)
Rear brake drum to shoe clearance0.6 mm (0.024 in.)
Parking brake lever travel at 196 N (20 kgf, 44 lbf)11 − 17 clicks

Downloaded from www.Manualslib.com manuals search engine SS085−01
SS−70
− SERVICE SPECIFICATIONSBRAKE
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.·lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket131309
Front disc brake caliper installation bolt 2WD 1.0 ton3940029
2WD 0.5 ton3637027
4WD1231,25090
Bleeder plug1111 08
Front disc brake torque plate x Steering knuckle 2WD1081,10080
Front disc x Front axle hub6465047
Front disc brake caliper x Flexible hose1515511
Rear drum brake wheel cylinder x Backing plate101007
Parking brake bellcrank bracket x Backing plate131309
LSP & BV installation nut131309
LSP & BV x Load Sensing Spring Assembly1818513
Load Sensing Spring Assembly x Shackle No.11818513
Shackle No.1 x Shackle No.22525018
Shackle No.2 x Shackle Bracket131309
LSP & BV x Frame2930011
ABS actuator x ABS actuator bracket5.45548 in.·lbf
ABS actuator bracket x Body1919514
Speed sensor installation bolt8.08271 in.·lbf
Front speed sensor wire harness clamp5.05144 in.·lbf
Rear speed sensor wire harness clamp131309