wheel alignment TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SS07T−01
− SERVICE SPECIFICATIONSCLUTCH
SS−41
215 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH
SERVICE DATA
Pedal height from flower panel154.6 − 164.6 mm (6.087 − 6.480 in.)
Pedal height from asphalt sheet Extra Cab (4WD)150.1 − 160.1 mm (5.909 − 6.303 in.)
Pedal height from asphalt sheet Others153.1 − 163.1 mm (6.027 − 6.421 in.)
Push rod play at pedal top1.0 − 5.0 mm (0.039 − 0.197 in.)
Pedal freeplay5.0 − 15.0 mm (0.197 − 0.591 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch start switch ON−OFF Stroke5.0 ± 0.5 mm (0.197 ± 0.020 in.)
Slotted spring pin protrusion1.5 − 3.5 mm (0.059 − 0.138 in.)
Disc rivet head depth Min.0.3 mm (0.012 in.)
Disc runoutMax.0.8 mm (0.031 in.)
Flywheel runout Max.0.1 mm (0.004 in.)
Diaphragm spring finger wear Max. depth0.6 mm (0.024 in.)
Diaphragm spring finger wear Max. width5.0 mm (0.197 in.)
Diaphragm spring tip non−alignmentMax.0.5 mm (0.020 in.)

Downloaded from www.Manualslib.com manuals search engine SS082−02
SS−58
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
232 Author: Date:
1996 TOYOTA T100 (RM449U)
SUSPENSION AND AXLE
SERVICE DATA
Cold tire inflation
pressure (2WD)
P215/75R15Front 230 kPa (2.3 kgf/cm2,
33 psi)
Rear 240 kPa (2.4 kgf/cm2, 35 psi)
P235/75R15 (0.5 ton)Front 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 200 kPa (2.0 kgf/cm2, 29 psi)
P235/75R15 (1.0 ton)Front 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 280 kPa (2.8 kgf/cm2, 41 psi)
Cold tire inflation
pressure (4WD)
P235/75R15STD cabFront 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 200 kPa (2.0 kgf/cm2, 29 psi)31x10.5R15LTSTD cab
P235/75R15Extra cabFront 180 kPa (1.8 kgf/cm2, 26 psi)
Rear 240 kPa (2.4 kgf/cm2, 35 psi)
31x10.5R15LTExtra cabFront 200 kPa (2.0 kgf/cm2, 29 psi)
Rear 240 kPa (2.4 kgf/cm2, 35 psi)
Wheel alignment
(Standard loaded
vehicle condition)
(2WD)
Vehicle height STD cab 0.5 ton
STD cab 1.0 ton
Extra cabFront *174.0 mm (2.913 in.)
Rear *2122.0 mm (4.803 in.)
Front *174.0 mm (2.913 in.)
Rear *2107.0 mm (4.213 in.)
Front *174.0 mm (2.913 in.)
Rear *2115.5 mm (4.547 in.)
Camber
Left−right error0°00’ ± 45’ (0° ± 0.75°)
45’ (0.75°) or less
Caster
Left−right error4°00’ ± 45’ (4° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error12°30’ ± 45’ (12.5° ± 0.75°)
45’ (0.75°) or less
To e−in (Total)STD cab
Extra cab (P215/75R15)
Extra cab (P235/75R15)
Rack end length difference0° ± 12’ (0° ± 0.2°, 0 ± 2 mm, 0 ± 0.08 in.)
−0°22’ ± 12’ (−0.36° ± 0.2°, 4.7 ± 2 mm, −0.18 ± 0.08 in.)
−0°22’ ± 12’ (−0.36° ± 0.2°, 4.9 ± 2 mm, −0.19 ± 0.08 in.)
3.0 mm (0.118 in.) or less
Wheel angle
STD cab 0.5 ton Inside wheel
Outside wheel
STD cab 1.0 ton Inside wheel
Outside wheel
Extra cab Inside wheel
Outside wheel
Left−right error
40°42’ ± 2° (40.7° ± 2°)
34°23’ (34.38°)
39°55’ ± 2° (39.92° ± 2°)
34°37’ (34.62°)
40°10’ ± 2° (40.17° ± 2°)
34°25’ (34.42°)
30’ (0.5°) or less
*1: A − B
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
*
2: C − D
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS−59
233 Author: Date:
1996 TOYOTA T100 (RM449U) Wheel alignment
(Non−loaded
vehicle condition)
(2WD)
Vehicle height
RCK10L−TRMRKA P215/75R15
Front*145.4 mm (1.787 in.)
Rear*262.5 mm (2.460 in.)
RCK10L−TRMRKA P235/75R15Front*145.4 mm (1.787 in.)
Rear*261.4 mm (2.417 in.)
RCK10L−TRSRKA P215/75R15Front*145.4 mm (1.787 in.)
Rear*263.5 mm (2.500 in.)
VCK11L−TRMDKA P215/75R15Front*148.0 mm (1.890 in.)
Rear*262.2 mm (2.449 in.)
VCK11L−TRMDKA P235/75R15Front*148.0 mm (1.890 in.)
Rear*263.3 mm (2.492 in.)
VCK11L−THMDKA 5VZ−FE Engine (1.0 ton)Front*149.4 mm (1.945 in.)
Rear*232.3 mm (1.272 in.)
VCK11L−TRSDKA P215/75R15Front*149.9 mm (1.965 in.)
Rear*263.5 mm (2.500 in.)
VCK11L−TRSDKA P235/75R15Front*149.9 mm (1.965 in.)
Rear*264.6 mm (2.543 in.)
VCK11L−THSDKA 5VZ−FE Engine (1.0 ton)Front*149.9 mm (1.965 in.)
Rear*233.0 mm (1.299 in.)
VCK11L−CRMDKA P215/75R15Front*138.8 mm (1.528 in.)
Rear*245.6 mm (1.795 in.)
VCK11L−CRMSKA P235/75R15Front*138.8 mm (1.528 in.)
Rear*245.8 mm (1.803 in.)
VCK11L−CRSDKA P215/75R15Front*138.8 mm (1.528 in.)
Rear*246.6 mm (1.835 in.)
VCK11L−CRSDKA P235/75R15Front*138.8 mm (1.528 in.)
Rear*245.5 mm (1.791 in.)
VCK11L−CRSSKA P235/75R15Front*138.8 mm (1.528 in.)
Rear*246.7 mm (1.839 in.)
VCK11L−CRMDKA P235/75R15Front*138.8 mm (1.528 in.)
Rear*244.6 mm (1.756 in.)
*1: A − B
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
*
2: C − D
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.

Downloaded from www.Manualslib.com manuals search engine SS−60
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
234 Author: Date:
1996 TOYOTA T100 (RM449U) Wheel alignment
(Non−loaded
vehicle condition)
(2WD)
Camber
STD cab 3RZ−FE, 5VZ−FE engine (0.5 ton)
STD cab 5VZ−FE engine (1.0 ton)
Extra cab
Left−right error
0°24’ ± 45’ (0.4° ± 0.75°)
0°22’ ± 45’ (0.37° ± 0.75°)
0°28’ ± 45’ (0.47° ± 0.75°)
45’ (0.75°) or less
Caster
STD cab 3RZ−FE, 5VZ−FE engine (0.5 ton)
STD cab 5VZ−FE engine 1.0 ton
Extra cab
Left−right error
2°28’ ± 45’ (2.47° ± 0.75°)
1°38’ ± 45’ (1.63° ± 0.75°)
2°04’ ± 45’ (2.06° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination STD cab 0.5 ton
STD cab 1.0 ton
Extra cab
Left−right error12°05’ ± 45’ (12.08° ± 0.75°)
12°10’ ± 45’ (12.17° ± 0.75°)
12°00’ ± 45’ (12° ± 0.75°)
45’ (0.75°) or less
To e−in (Total)
STD cab 3RZ−FE, 5VZ−FE engine (0.5 ton)
STD cab 5VZ−FE engine (1.0 ton)
Extra cab
Rack end length difference
0°11’ ± 12’ (0.19° ± 0.2°, 2.4 ± 2 mm, 0.09 ± 0.08 in.)
0°33’ ± 12’ (0.55° ± 0.2°, 7.0 ± 2 mm, 0.28 ± 0.08 in.)
0°20’ ± 12’ (0.33° ± 0.2°, 6.1 ± 2 mm, 0.24 ± 0.08 in.)
3.0 mm (0.118 in.) or less
Wheel angle
STD cab 3RZ−FE, 5VZ−FE engine (0.5 ton)
Inside wheel
Outside wheel
STD cab 5VZ−FE engine (1.0 ton) Inside wheel
Outside wheel
Extra cab Inside wheel
Outside wheel
Left−right error
40°42’ ± 2° (40.7° ± 2°)
35°07’ (35.12°)
40°23’ ± 2° (40.38° ± 2°)
35°31’ (35.52°)
40°50’ ± 2° (40.83° ± 2°)
35°41’ (35.68°)
30’ (0.5°) or less

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS−61
235 Author: Date:
1996 TOYOTA T100 (RM449U) Wheel alignment
(Standard loaded
vehicle condition)
(4WD)
Vehicle height STD cab
Extra cabFront *158.0 mm (2.283 in.)
Rear *223.0 mm (0.906 in.)
Front *158.0 mm (2.283 in.)
Rear *228.0 mm (1.102 in.)
Camber
Left−right error0°45’ ± 45’ (0.75° ± 0.75°)
45’ (0.75°) or less
Caster STD cab
Extra cab
Left−right error1°30’ ± 45’ (1.5° ± 0.75°)
1°20’ ± 45’ (1.33° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error11°50’ ± 45’ (11.83° ± 0.75°)
45’ (0.75°) or less
To e−in (Total)STD cab
Extra cab (P235/75R15)
Extra cab (31x10.5R15)
Rack end length difference0°05’ ± 12’ (0.08° ± 0.2°, 1.0 ± 2 mm, 0.04 ± 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.)
3.0 mm (0.118 in.) or less
Wheel angle
STD cab Inside wheel
Outside wheel
Extra cab Inside wheel
Outside wheel
Left−right error
32°01’ ± 2° (32.02° ± 2°)
30°12’ (30.2°)
32°14’ ± 2° (32.23° ± 2°)
29°59’ (29.99°)
30’ (0.5°) or less
Wheel alignment
(Non−loaded
vehicle condition)
(4WD)
Vehicle height
VCK21L−TRMDKA P235/75R15
Front*138.3 mm (1.508 in.)
Rear*270.7 mm (2.783 in.)
VCK21L−TRMDKA 31x10.5R15Front*138.3 mm (1.508 in.)
Rear*272.6 mm (2.858 in.)
VCK21L−TRSDKA P235/75R15Front*140.0 mm (1.575 in.)
Rear*269.5 mm (2.736 in.)
VCK21L−TRSDKA 31x10.5R15Front*140.0 mm (1.575 in.)
Rear*271.4 mm (2.811 in.)
VCK21L−CRM#KA P235/75R15Front*132.3 mm (1.272 in.)
Rear*277.2 mm (3.039 in.)
VCK21L−CRM#KA 31x10.5R15Front*132.3 mm (1.272 in.)
Rear*279.4 mm (3.126 in.)
VCK21L−CRS#KA P235/75R15Front*132.3 mm (1.272 in.)
Rear*276.2 mm (3.000 in.)
VCK21L−CRS#KA 31x10.5R15Front*132.3 mm (1.272 in.)
Rear*278.3 mm (3.083 in.)
#: Any letter is applicable.
*
1: A − B
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
*
2: C − D
C: Ground clearance of leaf spring front bushing center.
D: Ground clearance of rear axle shaft center.

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 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 CL02L−01
Q06647
5VZ−FE 3RZ−FE
SST Flywheel
Side
Q06958
1,4
7
3
62,58 Matchmarks
Q06641
SST
Z00762
Q06642
− CLUTCHCLUTCH UNIT
CL−19
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them and the
clutch cover in position.
SST 09301−00110
(b) Align the matchmarks on the clutch cover and flywheel.
(c) Torque the 6 bolts on the clutch cover in the order shown.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non−alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333−00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to the these parts.
Release fork and hub contact point
Release fork and push rod contact point
Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887−01706 (100g).
4. INSTALL BOOT, RELEASE BEARING AND FORK TO
TRANSMISSION
Install the boot and bearing to the release fork, and then install
them to the transmission.

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 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