wheel torque TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine PP0FT−01
− PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
PP−11 5
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Torque wrench
Bolt: Length: 35mm (1.38 in.) Pitch: 1.0 mm (0.039 in.)
Diam.: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam.: 360 mm (14.17 in.)Airbag disposal
vinyl bagAirbag disposal

Downloaded from www.Manualslib.com manuals search engine SS07U−03
SS−42
− SERVICE SPECIFICATIONSCLUTCH
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Clutch line union1515511
Master cylinder installation nut131309
Bleeder plug1111 08
Clutch cover x Flywheel1919514
Release cylinder installation bolt121209
Release fork support 5VZ−FE4748035
Release fork support 3RZ−FE3940029

Downloaded from www.Manualslib.com manuals search engine SS089−02
− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
SS−49
223 Author: Date:
1996 TOYOTA T100 (RM449U)
AUTOMATIC TRANSMISSION
SERVICE DATA
Line pressure (Wheel locked)
(3RZ−FE)
Engine idling
D position
R position
at stall (Throttle valve fully opened)
D position
R position
(5VZ−FE)
Engine idling
D position
R position
at stall (Throttle valve fully opened)
D position
R position
363 − 422 kPa (3.7 − 4.2 kgf/cm2, 53 − 61 psi)
490 − 588 kPa (5.0 − 6.0 kgf/cm2, 71 − 85 psi)
932 − 1,177 kPa (9.5 − 12.0 kgf/cm
2, 135 − 171 psi)
1,294 − 1,638 kPa (13.2 − 16.7 kgf/cm2, 188 − 238 psi)
363 − 422 kPa (3.7 − 4.2 kgf/cm
2, 53 − 61 psi)
608 − 696 kPa (6.2 − 7.1 kgf/cm2, 88 − 101 psi)
902 − 1,147 kPa (9.2 − 11.7 kgf/cm
2, 131 − 166 psi)
1,432 − 1,942 kPa (14.6 − 19.8 kgf/cm2, 208 − 282 psi)
Engine stall revolution (D and R positions) 3RZ−FE
5VZ−FE1,950 ± 150 rpm
2,150 ± 150 rpm
Time lag N → D position
N → R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed
(A/C OFF and N position)
700 ± 50 rpm
Throttle cable adjustment
(Throttle valve fully opened)Between boot end face and inner cable stopper
0 − 1 mm (0 − 0.04 in.)
Drive plate runoutMax.
Torque converter runoutMax.
Torque converter installation distance 3R−FE
5VZ−FE0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
More than 31.75 mm (1.2500 in.)
More than 17.95 mm (0.7067 in.)
Speedometer driven gear oil seal drive in depth 3RZ−FE
5VZ−FE20 mm (0.79 in.)
20 mm (0.79 in.)
Lock−up point
(3RZ−FE / A340E)
D position
(Throttle valve opening 5%) Lock−up ON
Lock−up OFF
(5VZ−FE / A340E)
D position
(Throttle valve opening 5%) Lock−up ON
Lock−up OFF
(5VZ−FE / A340F)
(Throttle valve opening 5%) Lock−up ON
Lock−up OFF
83 − 88 km/h (52 − 55 mph)
70 − 75 km/h (44 − 47 mph)
79 − 84 km/h (49 − 52 mph)
72 − 77 km/h (45 − 48 mph)
75 − 80 km/h (47 − 50 mph)
68 − 73 km/h (42 − 45 mph)

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 SS085−01
SS−70
− SERVICE SPECIFICATIONSBRAKE
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.·lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket131309
Front disc brake caliper installation bolt 2WD 1.0 ton3940029
2WD 0.5 ton3637027
4WD1231,25090
Bleeder plug1111 08
Front disc brake torque plate x Steering knuckle 2WD1081,10080
Front disc x Front axle hub6465047
Front disc brake caliper x Flexible hose1515511
Rear drum brake wheel cylinder x Backing plate101007
Parking brake bellcrank bracket x Backing plate131309
LSP & BV installation nut131309
LSP & BV x Load Sensing Spring Assembly1818513
Load Sensing Spring Assembly x Shackle No.11818513
Shackle No.1 x Shackle No.22525018
Shackle No.2 x Shackle Bracket131309
LSP & BV x Frame2930011
ABS actuator x ABS actuator bracket5.45548 in.·lbf
ABS actuator bracket x Body1919514
Speed sensor installation bolt8.08271 in.·lbf
Front speed sensor wire harness clamp5.05144 in.·lbf
Rear speed sensor wire harness clamp131309

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− SERVICE SPECIFICATIONSSTEERING
SS−71
245 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING
SERVICE DATA
ON−VEHICLE INSPECTION
Steering wheel freeplayMaximum30 mm (1.18 in.)
3RZ−FE:
Drive belt tension New belt135−185 lbf
Drive belt tension Used belt80−120 lbf
Oil level rise MaximumBelow 5 mm (0.20 in.)
5VZ−FE:
Drive belt tension New belt135−180 lbf
Drive belt tension Used belt85−120 lbf
Oil level rise MaximumBelow 5 mm (0.20 in.)
3RZ−FE and 5VZ−FE (2WD):
Oil pressure at idle speed with valve closedMinimum7,845 kPa (80 kgf/cm2, 1,138 psi)
5VZ−FE (4WD):
Oil pressure at idle speed with valve closedMinimum8,336 kPa (85 kgf/cm2, 1,209 psi)
Steering effort at idle speedMaximum8.3 N·m (85 kgf·cm, 73 in.·lbf)
TILT STEERING COLUMN
Pawl stopper
1 or A12.68 − 12.74 mm (0.4992 − 0.5016 in.)
2 or B12.61 − 12.67 mm (0.4965 − 0.4988 in.)
3 or C12.54 − 12.60 mm (0.4937 − 0.4961 in.)
4 or D12.47 − 12.53 mm (0.4909 − 0.4933 in.)
5 or E12.40 − 12.46 mm (0.4882 − 0.4906 in.)
6 or F12.33 − 12.39 mm (0.4854 − 0.4878 in.)
7 or G12.26 − 12.32 mm (0.4827 − 0.4850 in.)
PS VANE PUMP
3RZ−FE and 5VZ−FE:
Pump shaft and front housing bushing oil clearance STD0.03−0.05 mm (0.0012−0.0020 in.)
Pump shaft and front housing bushing oil clearanceMaximum0.07 mm (0.0028 in.)
Vane plate heightMinimum8.6 mm (0.339 in.)
Vane plate thicknessMinimum1.397 mm (0.0550 in.)
Vane plate lengthMinimum14.991 mm (0.5902 in.)
Vane plate and pump rotor groove clearanceMaximum0.035 mm (0.0014 in.)
Vane plate length Pump rotor and cam ring mark
None14.999−15.001 mm (0.59051−0.59059 in.)
114.997−14.999 mm (0.59043−0.59051 in.)
214.995−14.997 mm (0.59035−0.59043 in.)
314.993−14.995 mm (0.59027−0.59035 in.)
414.991−14.993 mm (0.59020−0.59027 in.)
Flow control valve spring lengthMinimum32.3 mm (1.272 in.)
Pump rotating torqueMaximum0.25 N·m (2.5 kgf·cm, 2.2 in.·lbf) or less
PS GEAR
2WD:
Steering rack runoutMaximum0.3 mm (0.0118 in.)

Downloaded from www.Manualslib.com manuals search engine SS08X−01
− SERVICE SPECIFICATIONSSTEERING
SS−73
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
STEERING COLUMN
NON−TILT STEERING COLUMN:
Steering wheel set nut3536026
Steering wheel pad set screw (Torx screw)9.09078 in.·lbf
Steering column assembly set bolt and nut2526019
Control shaft lever x Control shaft assembly AT3536026
Intermediate shaft x Control valve assembly 2WD3536026
Intermediate shaft x Worm gear valve assembly 4WD3536026
Sliding w/shaft york sub−assembly x Intermediate shaft3536026
Main shaft assembly x Sliding w/shaft york sub−assembly3536026
TILT STEERING COLUMN:
Steering wheel set nut3536026
Steering wheel pad set screw (Torx screw)9.09078 in.·lbf
Steering column assembly set bolt and nut2526019
Control shaft lever x Control shaft assembly AT3536026
Intermediate shaft x Control valve assembly 2WD3536026
Intermediate shaft x Worm gear valve assembly 4WD3536026
Sliding w/shaft york sub−assembly x Intermediate shaft3536026
Sliding york sub−assembly x Sliding w/shaft york sub−assembly3536026
Main shaft assembly x Sliding york sub−assembly3536026
Turn signal bracket set bolt7.88069 in.·lbf
Tilt lever assembly set bolt22017 in.·lbf
Tilt sub lever side pawl set bolt x nut5.96052 in.·lbf
Tilt lever retainer set nut1515011
Compression spring set bolt7.88069 in.·lbf
PS VANE PUMP
3RZ−FE and 5VZ−FE:
Union bolt x Pressure feed tube4747534
Pressure port union x Pump housing8385061
Bracket x Pump assembly 5VZ−FE4344032
Rear housing set bolt2424017
Oil reservoir set bolt Front131309
Rear2424017
Vane pump pulley set nut4344032
Vane pump assembly set bolt 3RZ−FE3940029
Vane pump assembly with bracket set bolt and nut 5VZ−FE3940029
PS GEAR
2WD:
Control valve housing x Rack housing1818513
Self−locking nut2525018
Rack housing cap6970051
Rack guide spring cap lock nut51 (60)521 (700)38 (51)
Rack x Rack end61 (83)618 (850)45 (62)

Downloaded from www.Manualslib.com manuals search engine SS08D−01
SS−76
− SERVICE SPECIFICATIONSSUPPLEMENTAL RESTRAINT SYSTEM
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Steering wheel3435025
Steering wheel pad8.89078 in.·lbf
Airbag sensor assembly2121015
Front airbag sensor2930022

Downloaded from www.Manualslib.com manuals search engine Q06793
N
R
P
AT5115
Neutral Basic line
Bolt
Groove
DI−272
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
(3) Return the No.1 gear shifting rod 2 notches to N
position.
(4) Set the shift lever to N position.
(5) While holding the shift lever lightly toward the R
position side, adjust the No.1 gear shifting rod nut.
(6) Tighten the No.1 gear shifting rod nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(7) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust the park/neutral position.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.If it
is not as stated above, carry out the following adjustment
procedure.
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)
(h) Check the idle speed.
Idle speed (In N position and air conditioner OFF):
3RZ−FE: 700 ± 50 rpm
5VZ−FE: 700 ± 50 rpm
6. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transmission and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the that at normal operating fluid temperature 50 − 80°C (122 − 176°F)
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm
(7) Do the same test in R position.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm

Downloaded from www.Manualslib.com manuals search engine Z11443
A
A B
Z11127
(6)(7)
(8) (9)
(10)
(1) (2)
(3)(4) (5)
Z15493
Up ward 90°
Painted Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
30. INSTALL REAR END PLATE
Install the rear end plate with the 3 bolts.
Torque:
Bolt A: 18 N·m (185 kgf·cm, 13 ft·lbf)
Bolt B: 20 N·m (200 kgf·cm, 14 ft·lbf)
31. M/T:
INSTALL FLYWHEEL
(a) Install and uniformly tighten 10 new bolts to the flywheel,
in several passes, in the sequence shown.
Torque: 26.5 N·m (270 kgf·cm, 19 ft·lbf)
(b) Mark the top of the flywheel bolt with paint.
(c) Retighten the flywheel bolts by 90° in the numerical order
shown above.
(d) Check that the painted mark is now at a 90° angle to the
top.
32. A/T:
INSTALL DRIVE PLATE
Install the front spacer, drive plate and rear spacer with the 10
bolts.
Torque: 74 N·m (750 kgf·cm, 56 ft·lbf)