power steering fluid TOYOTA T100 1996 Factory Owner's Guide

Downloaded from www.Manualslib.com manuals search engine SR07Z−01
R15251
SST
Fulcum Length
− STEERINGPOWER STEERING GEAR (2WD)
SR−71
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
Torque the 2 gear assembly set bolts and nut.
2. INSTALL MOUNT BRACKET AND GROMMET
(a) Install the grommet and mount bracket to the PS gear as-
sembly.
(b) Torque the 2 bolts.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
3. CONNECT PRESSURE FEED TUBE AND INSTALL
RETRUN TUBE
(a) Coat a new O−ring with power steering fluid and install it
to the tube.
(b) Using SST, connect the pressure feed tube and install the
return tube.
SST 09631−22020
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT RETURN HOSE
5. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
6. CONNECT RH AND LH TIE ROD ENDS
Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
7. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
8. CENTER SPIRAL CABLE
(See page SR−20)
9. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering column
main shaft.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
10. BLEED POWER STEERING SYSTEM
(See page SR−4)
11. CHECK STEERING WHEEL CENTER POINT
12. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
13. INSTALL STEERING WHEEL PAD
(See page SR−20)
14. CHECK FRONT WHEEL ALIGNMENT
(See page SA−7)

Downloaded from www.Manualslib.com manuals search engine Z18651
 Washer
 O−Ring
 No.1 Lock Nut Side Cover No.1 Hose Support Bracket Adjusting Screw Lock Nut
Sector Shaft Adjusting Screw
Cross Shaft
Power Piston
Plunger Guide Nut
Compression Spring
Power Piston Plunger
Power Piston Plunger Guide
Power Steering Gear HousingNeedle Roller Bearing
 Union Seat
 O−Ring
 Teflon RingWorm Gear Valve
Body Assembly
Metal Spacer
 Snap ring
Non−reusable part
Power Steering fluid
Molybdenum disulfide lithium base grease  O−Ring
 O−Ring
 Teflon Ring
 Oil Seal
61 (620, 45)
61 (620, 45)
: Specified torque
N·m (kgf·cm, ft·lbf)
46 (470, 34)
20 (205, 15)
− STEERINGPOWER STEERING GEAR (4WD)
SR−73
1747 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine Z14505
SST
Bearing
R14227
SST
SST
Bearing
R14228
Bearing SST 23.1 mm
(0.909 in.)SST
SST SST
R14324
SST
Bearing 89.0 mm
(3,504 in.)
SST
SST SST
− STEERINGPOWER STEERING GEAR (4WD)
SR−77
1996 TOYOTA T100 (RM449U)
(d) Using SST, remove the bearing from the gear housing.
SST 09612−65014 (09612−01030)
(e) Using SST, press out the bearing from the gear housing.
SST 09950−60010 (09951−00360, 09951−00420,
09952−06010), 09950−70010 (09951−07200)
(f) Coat a new bearing with molybdenum disulfide lithium
base grease.
(g) Using SST, press in the bearing, as shown in the illustra-
tion.
SST 09950−60010 (09951−00360, 09951−00420,
09952−06010), 09950−70010 (09951−07200)
(h) Coat a new bearing with molybdenum disulfide lithium
base grease.
(i) Using SST, press in the bearing, as shown in the illustra-
tion.
SST 09950−60010 (09951−00360, 09951−00420,
09952−06010), 09950−70010 (09951−07200)
(j) Coat a new O−ring and metal spacer with power steering
fluid.
(k) Install the O−ring and metal spacer.
(l) Using snap ring pliers, install a new snap ring.
(m) Coat a new teflon ring with power steering fluid.
(n) Form the teflon ring into a heart shape and install it by
hand.

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SST
SR3026 SR3004
W03370
SST
Oil Seal
SST
R01298
SR2804
SR−78
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
(o) Using SST, form the teflon ring.
SST 09630−00014 (09631−00121)
NOTICE:
The teflon ring must be squeezed before inserting the sec-
tor shaft or damage will result.
(p) Coat a new oil seal lip with power steering fluid.
(q) Using SST, drive the oil seal into the gear housing.
SST 09950−60010 (09951−00340, 09951−00430,
09952−06010), 09950−70010 (09951−07200)
NOTICE:
Make sure to install the oil seal facing the correct direction.
5. IF NECESSARY, REPLACE TEFLON RING AND
O−RING
(a) Using a screwdriver, remove the teflon ring and O−ring
from the worm gear valve body assembly.
NOTICE:
Be careful not to damage the worm gear valve body assem-
bly.
(b) Coat a new O−ring with power steering fluid and install it.
(c) Expand a new teflon ring with your fingers.
NOTICE:
Be careful not to overexpand the teflon ring.
(d) Install the teflon ring.
(e) Coat the teflon ring with power steering fluid and snug it
down with a piston ring compressor for 5 − 7 minutes.

Downloaded from www.Manualslib.com manuals search engine SR084−01
R15586
R15587
SST
R12202
Hexagon
Wrench SR−80
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR MOLYBDE-
NUM DISULFIDE LITHIUM BASE GREASE (See page
SR−72)
2. INSTALL WORM GEAR VALVE BODY ASSEMBLY
(a) Coat 2 new O−rings with power steering fluid and install
them to the gear housing.
(b) Install the valve body assembly into the gear housing.
NOTICE:
Ensure that the power piston nut does not come off
the worm shaft.
Be careful not to damage the teflon ring.
(c) Torque the 4 bolts.
Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
(d) Using SST and a torque wrench, check the valve body as-
sembly rotating torque.
SST 09616−00010
Rotating torque:
0.3 − 0.5 N·m (3 − 5.5 kgf·cm, 2.6 − 4.8 in.·lbf)
HINT:
Hold the worm gear to prevent it from turning.
If rotating torque is not correct, replace the worm gear valve
body assembly.
3. INSTALL POWER PISTON PLUNGER GUIDE, POWER
PISTON PLUNGER, COMPRESSION SPRING AND
POWER PISTON PLUNGER GUIDE NUT
(a) Coat a new O−ring with power steering fluid and install it
to the plunger guide nut.
(b) Install the plunger guide nut with a hexagon wrench (10
mm).
Torque: 20 N·m (205 kgf·cm, 15 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine R01241
R01286
SST
Matchmarks
R01287
SST
R01290
− STEERINGPOWER STEERING GEAR (4WD)
SR−81
1996 TOYOTA T100 (RM449U)
4. INSTALL SECTOR SHAFT AND SIDE COVER
(a) Coat a new O−ring with power steering fluid and install it
the side cover.
(b) Assemble the sector shaft to the side cover.
HINT:
Fully loosen the sector shaft adjusting screw.
(c) Set the power piston nut at the center of the gear housing.
(d) Install and push the sector shaft into the gear housing so
that the center teeth mesh together.
(e) Torque the 4 bolts in a diagonal pattern.
Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
5. DETERMINE CENTER POSITION
(a) Using SST, turn the worm gear valve body shaft so full
lock in both directions and determine the exact center.
SST 09616−00010
(b) Place matchmarks on the worm gear valve body shaft and
gear housing to show neutral position.
6. ADJUST SECTOR SHAFT ADJUSTING SCREW
(a) Install SST with a torque wrench on the worm gear valve
body shaft.
SST 09616−00010
(b) Turn the adjusting screw until the preload is within the
specification.
Preload (Turning):
0.2 − 0.4 N·m (2 − 4 kgf·cm, 1.7 − 3.5 in.·lbf)
7. INSTALL NEW SEAL WASHER
8. INSTALL ADJUSTING SCREW LOCK NUT
Torque the lock nut while holding the sector shaft adjusting
screw.
Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)