ball joint TOYOTA T100 1996 Factory Service Manual

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 − PREPARATIONENGINE MECHANICAL (3RZ−FE)
PP−3
52 Author: Date:
1996 TOYOTA T100 (RM449U)
(09248−05420)Valve Lifter Stopper
09325−20010Transmission Oil Plug
09330−00021Companion Flange Holding ToolCrankshaft pulley
09550−10012Replacer Set ”B”
(09252−10010)No. 1 Replacer Handle−Valve guide busing
09608−30012Front Hub & Drive Pinion Bearing
Tool Set−
(09951−07100)Handle 100Crankshaft rear oil seal
09636−20010Upper Ball Joint Dust Cover
ReplacerCrankshaft timing gear
09816−30010Oil Pressure Switch SocketKnock sensor
09843−18020Diagnosis Check Wire
09950−40010Puller B Set
(09951−04010)Hanger 150
(09952−04010)Slide Arm

Downloaded from www.Manualslib.com manuals search engine − PREPARATIONSUSPENSION AND AXLE
PP−89
138 Author: Date:
1996 TOYOTA T100 (RM449U)
09504−22011Differential Side Bearing
ReplacerFront differential
Rear differential
09506−30012Differential Drive Pinion Rear
Bearing Cone ReplacerFront differential
09506−35010Differential Drive Pinion Rear
Bearing ReplacerRear differential
09521−25011Rear Axle Shaft PullerRear axle
09523−36010Rear Axle Hub Guide ToolRear differential
(09558−10010)Rear Axle Shaft Oil Seal
Replacer−
09554−14010Differential Oil Seal ReplacerFront differential
09554−30011Differential Oil Seal ReplacerFront differential
09556−22010Drive Pinion Front Bearing
RemoverFront differential
Rear differential
09556−30010Drive Pinion Front Bearing
RemoverFront differential
09607−60020Front Wheel Adjusting Nut WrenchFront axle (4WD)
09628−62011Ball Joint PullerFront axle
Front suspension (4WD)
09636−20010Upper Ball Joint Dust Cover
ReplacerFront differential

Downloaded from www.Manualslib.com manuals search engine PP−104
− PREPARATIONSTEERING
153 Author: Date:
1996 TOYOTA T100 (RM449U)
(09612−01060)Claw ”E”PS gear (2WD)
09616−00010Steering Worm Bearing Adjusting
SocketPS gear (2WD, 4WD)
09623−30011Steering Worm Bearing & Oil Seal
ReplacerPS gear (2WD)
09628−62011Ball Joint PullerPS gear (4WD)
Steering linkage
09630−00014Power Steering Gear Housing
Overhaul Tool Set
(09631−00051)No.3 WrenchPS gear (4WD)
(09631−00121)Teflon Ring FormerPS gear (4WD)
(09631−00142)Overhaul StandPS gear (4WD)
09631−10021Rack Stopper WrenchPS gear (2WD)
09631−10030Oil Seal RemoverPS vane pump (3RZ−FE)
09631−12071Steering Rack Oil Seal Test ToolPS gear (2WD)
09631−20070Seal Ring GuidePS gear (2WD)
09631−20081Seal Ring ToolPS gear (2WD)

Downloaded from www.Manualslib.com manuals search engine SS−62
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
236 Author: Date:
1996 TOYOTA T100 (RM449U) Wheel alignment
(Non−loaded
vehicle condition)
(4WD)
Camber STD cab
Extra cab
Left−right error0°35’ ± 45’ (0.59° ± 0.75°)
0°40’ ± 45’ (0.66° ± 0.75°)
45’ (0.75°) or less
Caster STD cab
Extra cab
Left−right error0°59’ ± 45’ (0.98° ± 0.75°)
1°10’ ± 45’ (1.17° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error12°00’ ± 45’ (12° ± 0.75°)
45’ (0.75°) or less
To e−in (Total)STD cab
Extra cab (P235/75R15)
Extra cab (31x10.5R15)0°12’ ± 12’ (0.2° ± 0.2°, 2.7 ± 2 mm, 0.11 ± 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.)
Wheel angle
STD cab Inside wheel
Outside wheel
Extra cab Inside wheel
Outside wheel
32°45’ ± 2° (32.75° ± 2°)
30°31’ (30.52°)
33°07’ ± 2° (33.12° ± 2°)
30°31’ (30.52°)
Front axle (2WD)
Axle hub axial playMaximum0.05 mm (0.0020 in.)
Axle hub preload (at starting)Friction force plus
5.0 − 14.0 N (0.5 − 1.4 kgf, 1.1 − 3.1 in.)
Front axle (4WD)Axle hub preload (at starting)25 − 53 N (2.6 − 5.4 kgf, 5.7 − 11.9 lbf)
Front drive shaft thrust clearanceStandard0.1 − 0.5 mm (0.0039 − 0.0197 in.)
Front drive shaft
(4WD)Drive shaft length481.2 − 491.2 mm (18.945 − 19.339 in.)
Front suspension
(2WD)Upper ball joint turning torque2.0 − 3.9 N·m (20 − 40 kgf·cm, 17 − 34 in.·lbf)
Lower ball joint turning torque2.0 − 7.0 N·m (20 − 70 kgf·cm, 17 − 61 in.·lbf)
Front suspension
(4WD)Upper ball joint turning torque0.5 − 2.4 N·m (5 − 25 kgf·cm, 4 − 22 in.·lbf)
Lower ball joint turning torque2.0 − 3.9 N·m (20 − 40 kgf·cm, 17 − 34 in.·lbf)
Rear axleShaft runoutMaximum2.0 mm (0.079 in.)
Flange runoutMaximum0.1 mm (0.004 in.)
Front differential
(4WD)
Companion flange vertical runoutMaximum0.10 mm (0.0039 in.)
Companion flange lateral runout Maximum0.10 mm (0.0039 in.)
Drive pinion bearing preload (at starting)
New bearing
Reused bearing
1.2 − 1.9 N·m (12 − 19 kgf·cm, 10.4 − 16.5 in.·lbf)
0.6 − 1.0 N·m (6 − 10 kgf·cm, 5.2 − 8.7 in.·lbf)
Total preload (at starting)In addition to drive pinion preload
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
Pinion gear to side gear backlash0.05 − 0.20 mm (0.0020 − 0.0079 in.)
Drive pinion to ring gear backlash0.13 − 0.18 mm (0.0051 − 0.0070 in.)
Ring gear runoutMaximum0.07 mm (0.0028 in.)
Rear oil seal drive in depth1.5 mm (0.059 in.)
Side gear shaft tube LH side oil seal drive in depth2.5 mm (0.098 in.)
A.D.D. sleeve fork to clutch sleeve clearance0.35 mm (0.0138 in.)
Differential bearing press in depth2.0 mm (0.079 in.)

Downloaded from www.Manualslib.com manuals search engine SS083−02
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS−67
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Front (2WD)
Tie rod end lock nut5657041
Steering knuckle x Upper ball joint1081,10080
Steering knuckle x Lower ball joint1421,450105
Steering knuckle x Brake caliper1081,10080
Steering knuckle x Steering knuckle arm1831,870135
Dust cover x Steering knuckle1919514
Disc x Axle hub6465047
Upper suspension arm x Upper ball joint3132023
Lower suspension arm x Lower ball joint7576055
Torque arm x Lower suspension arm4950036
Shock absorber x Frame2525018
Lower suspension arm x Shock absorber1818513
Lower suspension arm x Stabilizer bar131309
Lower suspension arm shaft nut2062,100152
Upper suspension arm shaft x Frame9698071
Upper suspension arm shaft x Upper suspension arm1261,28093
Lower ball joint x Strut bar7576055
Strut bar x Frame1231,25090
Stabilizer bar link set nut131309
Stabilizer bar bracket x Frame3030622
Hub nut1031,05076
ABS speed sensor x Steering knuckle8.08271 in.·lbf
ABS Speed sensor wire harness x Upper suspension arm5.05144 in.·lbf
Front (4WD)
Knuckle stopper bolt lock nut4748035
Tie rod clamp bolt2222516
Steering knuckle x Upper ball joint1421,450105
Steering knuckle x Lower ball joint5859043
Steering knuckle x Brake caliper1231,25090
Flange x Axle hub3131523
Flange x Front drive shaft1818513
Axle hub bearing lock nut4748035
Oil seal x Dust cover1818513
Upper suspension arm x Upper ball joint3334025
Lower suspension arm x Lower ball joint1421,450105
Steering knuckle arm x Steering knuckle1831,870135
Upper suspension arm x Torque arm8789064
Upper suspension arm shaft lock nut2262,300166
Shock absorber x Frame2525018
Lower suspension arm x Shock absorber1371,400101
Lower suspension arm x Stabilizer bar2526019
Stabilizer bar bracket x Frame2930022

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.