4WD TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine IN02G−02
B01123
[2WD]
[4WD]
JACK POSITION
SUPPORT POSITIONFront Center of crossmember
Rear Under the rear differential
Safety stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IN−8
− INTRODUCTIONREPAIR INSTRUCTIONS
1996 TOYOTA T100 (RM449U)
VEHICLE LIFT AND SUPPORT LOCATIONS

Downloaded from www.Manualslib.com manuals search engine IN−32
− INTRODUCTIONTERMS
32 Author: Date:
1996 TOYOTA T100 (RM449U) T/M
Transmission
U/SUndersize
VCVVacuum Control Valve
VSVVacuum Switching Valve
VTVVacuum Transmitting Valve
w/With
w/oWithout
2WDTwo Wheel Drive Vehicles (4x2)
4WDFour Wheel Drive Vehicles (2x2)

Downloaded from www.Manualslib.com manuals search engine MA0055
MA014−01
− MAINTENANCEBRAKE
MA−7
42 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Inspect in a well−lighted area. Inspect the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before inspecting the front
brake.
(a) Check all brake lines and hoses for:
Damage
Wear
Deformation
Cracks
Corrosion
Leaks
Bends
Twists
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS
(2WD: See page BR−22)
(4WD: See page BR−25)
HINT:
If a squealing or scraping noise occurs from the brake during
driving, check the pad wear indicator.
If there are traces of the indicator contacting the disc rotor, the
disc pad should be replaced.
3. INSPECT REAR BRAKE LININGS AND DRUMS
(2WD: See page BR−42)
(4WD: See page BR−48)

Downloaded from www.Manualslib.com manuals search engine B02088
MA015−02
B02089
B02090
MA−8
− MAINTENANCECHASSIS
43 Author: Date:
1996 TOYOTA T100 (RM449U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay (See page SR−9).
(b) Check the steering linkage for looseness or damage.
Check that:
Tie rod ends and relay rod ends do not have exces-
sive play.
Dust seals are not damaged.
2WD:
Boot clamps are not loose.
2. INSPECT SRS AIRBAG (See page RS−2)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leaks.
If leakage is found, check for cause and repair.
4. 4WD:
INSPECT DRIVE SHAFT BOOTS
Inspect the drive shaft boots for clamp looseness, grease leak-
age or damage.
5. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.
(b) Inspect the dust cover for damage.

Downloaded from www.Manualslib.com manuals search engine B02091
Z04824
A/T
OK if coolOK if hot
Add if coolAdd if hot
B02092
B02093
− MAINTENANCECHASSIS
MA−9
44 Author: Date:
1996 TOYOTA T100 (RM449U)
6. 2WD:
CHECK OIL LEVEL IN MANUAL TRANSMISSION, AU-
TOMATIC TRANSMISSION AND DIFFERENTIAL
(a) Manual transmission:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Transmission oil (M/T):
R150: See page MT−5
W59: See page MT−5
(b) Automatic transmission:
Check that the fluid level is in the ”HOT” range at the nor-
mal operating temperature (70 − 80°C or 158 − 176°F)
and add as necessary.
NOTICE:
Do not overfill.
Transmission fluid (A/T): See page
DI−265
(c) Differential:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Differential oil: See page SA−154
7. 5VZ−FE (4WD):
CHECK OIL LEVEL IN MANUAL TRANSMISSION, AU-
TOMATIC TRANSMISSION, TRANSFER AND DIFFER-
ENTIAL
(a) Manual transmission:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Transmission oil (M/T):
R150F: See page MT−10

Downloaded from www.Manualslib.com manuals search engine Z04824
A/T
OK if coolOK if hot
Add if coolAdd if hot
B02094
B02095
MA−10
− MAINTENANCECHASSIS
45 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) Automatic transmission:
Check that the fluid level is in the ”HOT” range at the nor-
mal operating temperature (70 − 80°C or 158 − 176°F)
and add as necessary.
NOTICE:
Do not overfill.
Transmission fluid (A/T): See page
DI−265
(c) Transfer:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Transfer oil: See page TR−3
(d) Differential:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Front differential oil: See page SA−43
Rear differential oil: See page SA−154
8. REPLACE MANUAL TRANSMISSION, TRANSFER
(5VZ−FE: 4WD) AND DIFFERENTIAL OIL
(a) Transfer:
Remove the transfer cover.
(b) Remove the drain plug and drain the oil.
(c) Reinstall drain plug securely.
(d) Add new oil until it begins to run out of the filler hole.
(2WD) Transmission oil (M/T):
R150: See page MT−5
W59: See page MT−5

Downloaded from www.Manualslib.com manuals search engine B02096
B02097
B02098
2WD
4WD
− MAINTENANCECHASSIS
MA−11
46 Author: Date:
1996 TOYOTA T100 (RM449U)
(5VZ−FE: 4WD) Transmission oil (M/T):
R150F: See page MT−10
Transfer oil: See page
TR−3
Front differential oil: See page SA−43
Rear differential oil: See page SA−154
9. REPLACE AUTOMATIC TRANSMISSION FLUID
(a) Remove the drain plug(s) and drain the fluid.
(b) Reinstall the drain plug(s) securely.
(c) With the engine OFF, add new fluid through the dipstick
tube.
Transmission fluid (A/T): See page DI−265
(d) Start the engine and shift the selector into all positions
from ”P” through ”L” and then shift into ”P”.
(e) With the engine idling, check the fluid level.
Add fluid up to the ”COOL” level on the dipstick.

Downloaded from www.Manualslib.com manuals search engine MA0099
OK if coolOK if hot
Add if coolAdd if hot
MA−12
− MAINTENANCECHASSIS
47 Author: Date:
1996 TOYOTA T100 (RM449U)
(f) Check that the fluid level is in the ”HOT” range at the nor-
mal operating temperature (70 − 80°C or 158 − 176°F)
and add as necessary.
NOTICE:
Do not overfill.
10. REPACK FRONT WHEEL BEARINGS AND THRUST
BUSH
(a) Change the front wheel bearing grease.
(2WD: See page SA−19)
(4WD: See page SA−25)
(b) Repack the drive shaft thrust bush grease (See page
SA−41).
11. 4WD:
LUBRICATE PROPELLER SHAFT
Lubricate propeller shaft, referring to the lubrication chart. Be-
fore pumping in grease, wipe off any mud and dust on the
grease fitting.
Grease grade:
Propeller shaft (Except Double−cardan joint)
Lithium base chassis grease NLGI No.2
Double−cardan joint
Molybdenum disulphide lithium base chassis grease
NLGI No.2

Downloaded from www.Manualslib.com manuals search engine PP336−02
− PREPARATIONCOOLING (5VZ−FE)
PP−31
1996 TOYOTA T100 (RM449U)
COOLANT
ItemCapacityClassification
2WD
M/T
A/T
4WD
M/T
A/T
10.0 liters (10.6 US qts, 8.8 lmp. qts)
9.9 liters (10.5 US qts, 8.7 lmp. qts)
10.0 liters (10.6 US qts, 8.8 lmp. qts)
10.2 liters (10.8 US qts, 9.0 lmp. qts)
Ethylene−glycol base

Downloaded from www.Manualslib.com manuals search engine PP01U−07
− PREPARATIONLUBRICATION (5VZ−FE)
PP−41
1996 TOYOTA T100 (RM449U)
LUBRICANT
ItemCapacityClassification
Engine oil
2WD
Dry fill
Drain and refill
w/ Oil filter change
w/o Oil filter change
4WD
Dry fill
Drain and refill
w/ Oil filter change
w/o Oil filter change
5.9 liters (6.2 US qts, 5.2 lmp. qts)
5.2 liters (5.5 US qts, 4.6 lmp. qts)
5.2 liters (5.5 US qts, 4.6 lmp. qts)
4.9 liters (5.2 US qts, 4.3 lmp. qts)
5.5 liters (5.8 US qts, 4.8 lmp. qts)
4.7 liters (5.0 US qts, 4.1 lmp. qts)
4.4 liters (4.7 US qts, 3.9 lmp. qts)
API grade SH, Energy−Conserving II multigrade
engine oil or ILSAC multigrade engine oil and
recommended viscosity oil, with SAE 5W−30
being preferred engine oil