4WD TOYOTA T100 1996 Factory Owner's Manual

Downloaded from www.Manualslib.com manuals search engine − PREPARATIONSTEERING
PP−105
154 Author: Date:
1996 TOYOTA T100 (RM449U)
09631−22020Power Steering Hose Nut
14 x 17 mm Wrench SetPS gear (2WD, 4WD)
09631−33010Steering Rack Cover ”I”PS gear (2WD)
09633−00020Power Steering Hose Nut WrenchPS gear (2WD)
09640−10010Power Steering Pressure Gauge
Set
(09641−01010)Gauge AssyOn−vehicle inspection
(09641−01030)Attachment BOn−vehicle inspection
(09641−01060)Attachment EOn−vehicle inspection
09910−00015Puller Set
(09911−00011)Puller ClampTilt steering column
(09912−00010)Puller Slide HammerTilt steering column
09922−10010Variable Open WrenchPS gear (2WD)
09950−40010Puller B Set
(09957−04010)AttachmentTilt steering column

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PP−107
156 Author: Date:
1996 TOYOTA T100 (RM449U)
(09951−00320)Replacer 32PS gear (2WD)
(09951−00340)Replacer 34PS gear (2WD, 4WD)
(09951−00360)Replacer 36PS gear (4WD)
(09951−00410)Replacer 41PS gear (2WD)
(09951−00420)Replacer 42PS gear (4WD)
(09951−00430)Replacer 43PS gear (2WD, 4WD)
(09952−06010)AdapterPS gear (2WD, 4WD)
09950−70010Handle Set
(09951−07150)Handle 150PS gear (2WD)
(09951−07200)Handle 200PS gear (2WD, 4WD)
Idler arm
(09951−07360)Handle 360PS gear (2WD)
09960−10010Variable Pin Wrench Set
(09962−01000)Variable Pin Wrench Arm AssyPS vane pump (3RZ−FE, 5VZ−FE)

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− PREPARATIONSTEERING
PP−109
1996 TOYOTA T100 (RM449U)
RECOMMENDED TOOLS
09025−00010Torque Wrench (30 ) .PS vane pump (3RZ−FE, 5VZ−FE)
PS gear (2WD, 4WD)
Idler arm
09042−00010Torx Socket T30 .Non−tilt steering column
Tilt steering column
09043−38100Hexagon 10 mm WrenchPS gear (4WD)
09904−00010Expander Set .
(09904−00050)No. 4 Claw
09905−00012Snap Ring No.1 Expander .
09905−00013Snap Ring Pliers .

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PP−11 0
− PREPARATIONSTEERING
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Belt tension gaugeOn−vehicle inspection
Caliper gaugePS vane pump (3RZ−FE, 5VZ−FE)
CalipersPS vane pump (3RZ−FE, 5VZ−FE)
Dial indicatorPS gear (2WD, 4WD)
Feeler gaugePS vane pump (3RZ−FE, 5VZ−FE)
MicrometerPS vane pump (3RZ−FE, 5VZ−FE)
Torque wrench

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− SERVICE SPECIFICATIONSCLUTCH
SS−41
215 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH
SERVICE DATA
Pedal height from flower panel154.6 − 164.6 mm (6.087 − 6.480 in.)
Pedal height from asphalt sheet Extra Cab (4WD)150.1 − 160.1 mm (5.909 − 6.303 in.)
Pedal height from asphalt sheet Others153.1 − 163.1 mm (6.027 − 6.421 in.)
Push rod play at pedal top1.0 − 5.0 mm (0.039 − 0.197 in.)
Pedal freeplay5.0 − 15.0 mm (0.197 − 0.591 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch start switch ON−OFF Stroke5.0 ± 0.5 mm (0.197 ± 0.020 in.)
Slotted spring pin protrusion1.5 − 3.5 mm (0.059 − 0.138 in.)
Disc rivet head depth Min.0.3 mm (0.012 in.)
Disc runoutMax.0.8 mm (0.031 in.)
Flywheel runout Max.0.1 mm (0.004 in.)
Diaphragm spring finger wear Max. depth0.6 mm (0.024 in.)
Diaphragm spring finger wear Max. width5.0 mm (0.197 in.)
Diaphragm spring tip non−alignmentMax.0.5 mm (0.020 in.)

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− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (R150, R150F)
SS−45
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transmission x Engine7273053
Stiffener plate x Engine (4WD)3738027
Stiffener plate x Transmission (4WD)3738027
Starter x Transmission3940029
Engine rear mounting x Transmission6566048
Rear end plate x Transmission (2WD)1818513
Clutch release cylinder x Transmission121209
Front exhaust pipe x TWC4849035
Front exhaust pipe support bracket4445033
Front exhaust pipe x Exhaust manifold6263046
Crossmember x Engine rear mounting (4WD)1818013
Engine rear mounting bracket x Engine rear mounting (2WD)1818013
Engine rear mounting bracket x Frame (2WD)5859043
Crossmember x Frame (4WD)9597070
Transmission x Transfer (4WD)3738027
Reverse shift arm bracket set bolt1818513
Rear bearing retainer x Intermediate plate1818513
Shift fork x Shift fork shaft2020014
Straight screw plug1919014
Front bearing retainer x Transmission case1717012
Transmission case x Transfer adaptor3738027
Transmission case x Extension housing3738027
Shift lever housing set bolt3839028
Clutch housing x Transmission case3637027
Oil receiver x Extension housing1111 58
Back−up light switch4445032
Restrict pin3738027
Control shift lever retainer x Transfer adaptor1818513
Control shift lever retainer x Extension housing1818513
Filler and drain plug3738027
Speedometer driven gear (2WD)1111 58

Downloaded from www.Manualslib.com manuals search engine SS07Y−01
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.

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.