ABS TOYOTA T100 1996 Factory Workshop Manual

Downloaded from www.Manualslib.com manuals search engine P20975
CO062−01
− COOLING (5VZ−FE)RADIATOR
CO−17
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE NO.1 FAN SHROUD.
Remove the 4 bolts and No.1 fan shroud.
2. REMOVE RADIATOR SUPPORTS
Using a torx wrench, remove the 8 torx screws and the 2 radia-
tor supports.
Torx wrench: T30 (Part No. 09042−00010 or locally manufac-
tured tool)
HINT:
Insert the tabs the radiator upper tank through the radiator sup-
port holes.

Downloaded from www.Manualslib.com manuals search engine CL026−01
− CLUTCHTROUBLESHOOTING
CL−1
1236 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
3. Clutch disc (Oily)
4. Clutch disc (Worn out)
5. Clutch disc (Damaged torsion rubber)
6. Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment)−
CL−15
CL−15
CL−15
CL−15
CL−15
CL−19
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged)−
CL−5
CL−10
Clutch noisy
1. Release bearing (Worn, dirty or damaged)
2. Input shaft bearing (Worn, dirty or damaged)
3. Clutch disc torsion rubber (Damaged)CL−15
−
CL−15
Clutch slips
1. Clutch pedal (Freeplay out of adjustment)
2. Clutch disc (Oily)
3. Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel (Distortion)CL−2
CL−15
CL−15
CL−15
CL−15
−
Clutch does not disengage
1. Clutch pedal (Freeplay out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder cup (Damaged)
4. Release cylinder cup (Damaged)
5. Input shaft bearing (Worn, dirty or damaged)
6. Clutch disc (Out of true)
7. Clutch disc (Runout is excessive)
8. Clutch disc (Lining broken)
9. Clutch disc (Dirty or burred)
10. Clutch disc (Oily)
11. Clutch disc (Lack of spline grease)
12. Diaphragm spring (Damaged)
13. Diaphragm spring (Out of tip alignment)
14. Pressure plate (Distortion)CL−2
−
CL−5
CL−10
−
CL−15
CL−15
CL−15
CL−15
CL−15
CL−19
CL−15
CL−19
CL−15

Downloaded from www.Manualslib.com manuals search engine SA – SUSPENSION AND AXLE

TROUBLESHOOTING SA-1

TIRE AND WHEEL (2WD) SA-3
TIRE AND WHEEL (4WD) SA-5
FRONT WHEEL ALIGNMENT (2WD) SA-7
FRONT WHEEL ALIGNMENT (4WD) SA-10
FRONT AXLE HUB (2WD) SA-15
FRONT AXLE HUB (4WD) SA-22
FRONT WHEEL HUB BOLT (2WD) SA-27
STEERING KNUCKLE (4WD) SA-28
FRONT DRIVE SHAFT (4WD) SA-36
FRONT DIFFERENTIAL REAR OIL
SEAL (4WD) SA-42
FRONT DIFFERENTIAL CARRIER
(4WD) SA-45
A.D.D. CONTROL SYSTEM SA-69
FRONT SHOCK ABSORBER (2WD) SA-72
FRONT SHOCK ABSORBER (4WD) SA-77
FRONT TORSION BAR SPRING (2WD) SA-82
FRONT TORSION BAR SPRING (2WD) SA-85
FRONT STRUT BAR (2WD) SA-88
FRONT UPPER SUSPENSION ARM
(2WD) SA-91
FRONT UPPER SUSPENSION ARM
(4WD) SA-95
FRONT LOWER SUSPENSION ARM
(2WD) SA-99
FRONT LOWER SUSPENSION ARM
(4WD) SA-103

Downloaded from www.Manualslib.com manuals search engine SA – SUSPENSION AND AXLE

FRONT UPPER BALL JOINT (2WD) SA-107
FRONT UPPER BALL JOINT (4WD) SA-111
FRONT LOWER BALL JOINT (2WD) SA-115
FRONT LOWER BALL JOINT (4WD) SA-119
FRONT STABILIZER BAR (2WD) SA-123
FRONT STABILIZER BAR (4WD) SA-126
REAR AXLE SHAFT SA-129
REAR WHEEL HUB BOLT SA-136
REAR DIFFERENTIAL CARRIER SA-137
REAR SHOCK ABSORBER SA-155
REAR LEAF SPRING SA-160

Downloaded from www.Manualslib.com manuals search engine SA0FC−01
− SUSPENSION AND AXLETROUBLESHOOTING
SA−1
1440 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Wander/pulls
1. Tires (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering linkage (Loosen or worn)
4. Hub bearings (Loosen or worn)
5. Suspension parts (Worn out)
6. Steering gear (Out of adjustment or broken)SA−3
SA−5
SA−7
SA−10
−
SA−15
SA−22
SA−129
−
−
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn out)−
SA−82
SA−85
SA−160
SA−72
SA−77
SA−155
Sways/pitches
1. Tires (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn out)SA−3
SA−5
SA−123
SA−126
SA−72
SA−77
SA−155
Front wheel shimmy
1. Tires (Worn or improperly inflated)
2. Wheels (Out of balance)
3. Shock absorber (Worn out)
4. Wheel alignment (Incorrect)
5. Ball joints (Worn)
6. Hub bearings (Loosen or worn)
7. Steering linkage (Loosen or worn)
8. Steering gear (Out of adjustment or broken)SA−3
SA−5
SA−3
SA−5
SA−72
SA−77
SA−155
SA−7
SA−10
SA−107
SA−11 1
SA−11 5
SA−11 9
SA−15
SA−22
SA−129
−
−
Abnormal tire wear
1. Tires (Improperly inflated)
2. Wheel alignment (Incorrect)
3. Suspension parts (Worn out)
4. Shock absorber (Worn out)SA−3
SA−5
SA−3
SA−5
−
SA−72
SA−77
SA−155

Downloaded from www.Manualslib.com manuals search engine R04258
SA−4
− SUSPENSION AND AXLETIRE AND WHEEL (2WD)
1443 Author: Date:
1996 TOYOTA T100 (RM449U)
4. CHECK WHEEL BEARING LOOSENESS
Check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
5. CHECK FRONT SUSPENSION FOR LOOSENESS
6. CHECK STEERING LINKAGE FOR LOOSENESS
7. CHECK BALL JOINT FOR LOOSENESS
8. CHECK SHOCK ABSORBER WORKS PROPERLY
Check for oil leaks.
Check mounting bushings for wear.
Check front and rear of the vehicle for bounce.

Downloaded from www.Manualslib.com manuals search engine SA−6
− SUSPENSION AND AXLETIRE AND WHEEL (4WD)
1445 Author: Date:
1996 TOYOTA T100 (RM449U)
4. CHECK FRONT SUSPENSION FOR LOOSENESS
5. CHECK STEERING LINKAGE FOR LOOSENESS
6. CHECK BALL JOINT FOR LOOSENESS
7. CHECK SHOCK ABSORBER WORKS PROPERLY
Check for oil leaks.
Check mounting bushings for wear.
Check front and rear of the vehicle for bounce.

Downloaded from www.Manualslib.com manuals search engine SA0FI−01
W00397
R04268
FA0026
SST SA−16
− SUSPENSION AND AXLEFRONT AXLE HUB (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
2. w/ ABS:
DISCONNECT ABS SPEED SENSOR FROM
STEERING KNUCKLE
3. REMOVE BRAKE CALIPER
(a) Remove the 2 brake caliper set bolts.
(b) Support the brake caliper securely.
4. CHECK AXLE HUB BEARING BACKLASH
(a) Remove the cap, cotter pin and lock cap.
(b) Using a dial indicator near the center of the axle hub and
check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash is not within the specification replace the bear-
ing.
5. REMOVE AXLE HUB WITH DISC
(a) Using a 30 mm socket, remove the nut.
(b) Remove the axle hub with the disc together with the outer
bearing from the steering knuckle.
NOTICE:
Be careful not to drop the outer bearing.
6. REMOVE OIL SEAL AND INNER BEARING
(a) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
(b) Remove the inner bearing from the axle hub.
7. REMOVE DUST COVER
Remove the 3 bolts and dust cover.
8. DISCONNECT KNUCKLE ARM FROM STEERING
KNUCKLE
Remove the 2 bolts and disconnect the knuckle arm from the
steering knuckle.
9. REMOVE STEERING KNUCKLE
(a) Support the lower suspension arm with a jack.
(b) Remove the upper and lower cotter pins.
(c) Remove the upper and lower nuts.
(d) Using SST, disconnect the steering knuckle from the up-
per and lower ball joints.
SST 09628−62011
(e) Remove the steering knuckle.

Downloaded from www.Manualslib.com manuals search engine SA0FK−01
SA0171
R11699
SST SA−18
− SUSPENSION AND AXLEFRONT AXLE HUB (2WD)
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. INSPECT BEARINGS
Clean the bearings and outer races and inspect them for wear
or damage.
2. REPLACE BEARING OUTER RACES
(a) Using a brass bar and hammer, remove the inside and
outside bearing outer races.
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
(b) Using SST and a press, install a new outside bearing out-
er race.
SST 09950−60010 (09951−00480),
09950−70010 (09951−07150)
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
(c) Using SST and a press, install a new inside bearing outer
race.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)

Downloaded from www.Manualslib.com manuals search engine R12255
SST
R04262
R11763
90°
R11764
90° SA−20
− SUSPENSION AND AXLEFRONT AXLE HUB (2WD)
1996 TOYOTA T100 (RM449U)
6. INSTALL INNER BEARING AND OIL SEAL
(a) Place inner bearing into the axle hub.
(b) Using SST and a hammer, install a new oil seal into the
hub.
SST 09950−60020 (09951−00710),
09950−70010 (09951−00150)
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
(c) Coat the oil seal lip with MP grease.
7. INSTALL AXLE HUB WITH DISC
(a) Place the axle hub on the spindle.
(b) Install the outer bearing and thrust washer.
8. ADJUST PRELOAD
(a) Install and torque the nut.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
(b) Turn the hub several times to make the bearing more
smoothly
(c) Loosen the nut until it can be turned by hand.
(d) Using a spring tension gauge, measure and make a note
of the frictional force of the oil seal.
Preload (at starting): 4.0 N (0.4 kgf, 0.9 lbf) or less
HINT:
Make sure to check preload in the direction of rotation.
(e) Tighten the nut until the preload is within specification.
Preload (at starting) :
Frictional force plus
5.0 − 14.0 N (0.5 − 1.4 kgf, 1.1 − 3.1 lbf)
HINT:
Make sure to check preload in the direction of rotation.