clock TOYOTA T100 1996 Factory Owner's Manual

Downloaded from www.Manualslib.com manuals search engine P13486
CH0HX−01
P13762
Upward
P13487
29 mm
Socket
Wrench
P13597
SST (A)
SST (B)TurnTurn
P10834
SST (C)SST (B)
Insert CH−14
− CHARGING (3RZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation directon.
4. INSTALL RECTIFIER END FRAME
(a) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(b) Install the 4 nuts.
Torque: 4.5 N·m (46 kgf·cm, 39 in.·lbf)
5. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

Downloaded from www.Manualslib.com manuals search engine CH0HZ−01
P13397
P13398
P13396
P20344
CH0213
SST (A)SST (B)
− CHARGING (5VZ−FE)GENERATOR
CH−7
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the 3 nuts and end cover.
2. REMOVE BRUSH HOLDER
(a) Remove the 2 screws, brush holder and cover.
(b) Remove the brush holder cover from the brush holder.
3. REMOVE VOLTAGE REGULATOR
Remove the 3 screws and voltage regulator.
4. REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
5. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63010
Torque:39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.

Downloaded from www.Manualslib.com manuals search engine CH02N−03
P13486
P13762
Upward
P13487
Wrench Socket
29 mm
P13597
SST (B)SST (A)
P10834
SST (B)
SST (C)Insert
− CHARGING (5VZ−FE)GENERATOR
CH−13
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation direction.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Install the 4 nuts.
Torque:4.5 N·m (46 kgf·cm, 39 in.·lbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63010
Torque:39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

Downloaded from www.Manualslib.com manuals search engine MT0501
Down
ClothCounterclockwise
MT0ER−01
D10948
MT−4
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION WITH ENGINE (See page
EM−65)
2. REMOVE REAR END PLATE
Remove the 4 bolts, nuts and rear end plate.
Torque:37 N·m (380 kgf·cm, 27 ft·lbf)
3. REMOVE STARTER
Remove the 2 bolts and starter.
Torque:39 N·m (400 kgf·cm, 29 ft·lbf)
4. REMOVE TRANSMISSION FROM ENGINE
(a) Remove the 6 transmission mounting bolts from the en-
gine.
Torque:72 N·m (730 kgf·cm, 53 ft·lbf)
(b) Pull out the transmission toward the rear.
5. REMOVE ENGINE REAR MOUNTING
(a) Remove the 4 bolts and engine rear mounting.
Torque:25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Lower the front side of the transmission and remove it
from the front side of the vehicle.

Downloaded from www.Manualslib.com manuals search engine MT0501
Down
ClothCounterclockwise
MT04O−02
Q06817
Installation
Front
Select Return Spring
Tip of Shift Lever
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
MT−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION SHIFT LEVER
(a) Remove the 4 screws and front console box.
(b) Remove the 4 screws and shift lever boot retainer.
(c) Cover the shift lever cap with a cloth.
(d) Then, pressing down on the shift lever cap, rotate it coun-
terclockwise to remove.
(e) Pull out the shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of the shift lever.
2. REMOVE TRANSFER SHIFT LEVER
Using snap ring pliers, remove the snap ring and pull out the
shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of shift lever.
3. RAISE VEHICLE AND DRAIN TRANSMISSION OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 2.2 liters (2.3 US qts, 1.9 Imp. qts)
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE FRONT AND REAR PROPELLER SHAFTS
(See page PR−10)
5. DISCONNECT SPEEDOMETER CABLE
6. DISCONNECT BACK−UP LIGHT SWITCH AND 4WD
INDICATOR SWITCH CONNECTORS
7. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
Remove the 4 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine AT0953
SST
AT02G−06
AT3306
Free Lock Hold
Turn
D00843
AT−38
− AUTOMATIC TRANSMISSIONTORQUE CONVERTER CLUTCH AND DRIVE PLATE
1379 Author: Date:
1996 TOYOTA T100 (RM449U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE−WAY CLUTCH
(a) Install SST in the inner race of one−way clutch.
SST 09350−30020 (09351−32010)
(b) Install SST so that it fits in the notch of the converter hub
and outer race of the one−way clutch.
SST 09350−30020 (09351−32020)
(c) With the torque converter clutch standing on its side,
check that the clutch locks when turned counterclock-
wise, and rotates freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch.
(d) Replace the converter if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If runout is not within the specification or if the ring gear is dam-
aged, replace the drive plate.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)

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 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.

Downloaded from www.Manualslib.com manuals search engine R13023
Vinyl Tape
R04594
SSTWire
R15247
SST
− STEERINGPOWER STEERING GEAR (2WD)
SR−59
1996 TOYOTA T100 (RM449U)
13. REMOVE CONTROL VALVE ASSEMBLY
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the valve shaft.
(b) Using a plastic hammer, tap out the valve with the oil seal
from the control valve housing.
NOTICE:
Be careful not to damage the oil seal lip.
(c) Remove the oil seal from the valve assembly.
14. REMOVE CYLINDER END STOPPER
(a) Using SST, turn the stopper clockwise until the wire end
comes out.
SST 09631−10021
(b) Using SST, turn the stopper counterclockwise, and re-
move the wire.
SST 09631−10021
15. REMOVE STEERING RACK AND RACK BUSHING
(a) Using a brass bar and a hammer, tap out the rack with the
rack busing.
(b) Remove the O−ring from the bushing.
16. REMOVE OIL SEAL
Using SST and a brass bar, drive out the oil seal from the rack
housing.
SST 09623−30011

Downloaded from www.Manualslib.com manuals search engine R13021
Vinyl Tape
R15248
Wire
SST
Cylinder End
Stopper
R04609
SST
R13031
Vinyl Tape
W03369
SST
Oil Seal
− STEERINGPOWER STEERING GEAR (2WD)
SR−65
1996 TOYOTA T100 (RM449U)
4. INSTALL RACK BUSHING AND CYLINDER END
STOPPER
(a) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(b) Coat a new O−ring with power steering fluid and install it
to the bushing.
(c) Push in the bushing.
NOTICE:
Make sure to install the bushing facing the correct direc-
tion.
(d) Push in the cylinder end stopper until the wire installation
hole appears.
5. INSTALL WIRE
(a) Insert a new wire end into the hole of the rack housing.
(b) Using SST, turn the cylinder end stopper clockwise until
the wire end disappears.
SST 09631−10021
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631−12071
(b) Apply 53.3 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the valve shaft.
(c) Install the valve assembly into the control valve housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.
8. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09612−22011
NOTICE:
Make sure to install the oil seal facing the correct direction.