1996 TOYOTA T100 relay

Downloaded from www.Manualslib.com manuals search engine SR081−01
R08049
SST
R12957
SST SR−74
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD
(See page SR−13)
3. REMOVE STEERING WHEEL
(See page SR−13)
4. DISCONNECT PITMAN ARM SUB−ASSEMBLY WITH
RELAY ROD
(a) Remove the pitman arm set nut and spring washer.
(b) Using SST, disconnect the pitman arm from the gear as-
sembly.
SST 09628−62011
5. DISCONNECT PRESSURE FEED TUBE AND RETURN
TUBE
Using SST, disconnect the tube.
SST 09631−22020
6. DISCONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−13)
7. REMOVE PS GEAR ASSEMBLY
Remove the 3 bolts, nuts and washers.

Downloaded from www.Manualslib.com manuals search engine SR085−01
R15509
Fulcrum
Length
SST
SR2922
Alignment Marks
− STEERINGPOWER STEERING GEAR (4WD)
SR−83
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Install the 3 bolts, washers and nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
2. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
3. CONNECT PRESSURE FEED TUBE AND RETURN
TUBE
Using SST, connect the tube.
SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT PITMAN ARM SUB−ASSEMBLY WITH
RELAY ROD
(a) Align the alignment marks on the pitman arm and sector
shaft, and connect the pitman arm.
(b) Install the spring washer and pitman arm set nut.
Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
5. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
6. CENTER SPIRAL CABLE
(See page SR−20)
7. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering column
main shaft.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
8. BLEED POWER STEERING SYSTEM
(See page SR−4)
9. CHECK STEERING WHEEL CENTER POINT
10. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
11. INSTALL STEERING WHEEL PAD
(See page SR−20)
12. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)

Downloaded from www.Manualslib.com manuals search engine R15252
RH Tie Rod End
Sub−Assembly
RH Knuckle Arm
Steering Damper
 Non−reusable partEngine Under CoverSpring WasherPitman ArmLH Knuckle Arm LH Tie Rod Sub−Assembly
LH Tie Rod End Assembly RH Tie Rod
Idler Arm
Assembly
Relay Rod
 Cotter PinLH Tie Rod
Assembly Clamp
Tie Rod
Clamp
Clamp
Tie Rod
Clamp
Sub−Assembly
Sub−Assembly RH Tie Rod
 
 22 (225, 16)
22 (225, 16)
22 (225, 16)
22 (225, 16)
90 (920, 67)
177 (1800, 130)
90 (920, 67)
25 (260, 19)
59 (600, 43)
90 (920, 67)
90 (920, 67)
142 (1450, 105)
: Specified torque
N·m (kgf·cm, ft·lbf)
59 (600, 43)
SR086−01
SR−84
− STEERINGSTEERING LINKAGE
1758 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING LINKAGE
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine SR087−01
R08049
SST
R15244
SST
R04470
SST
SR1254
SST
SR1260
SST
− STEERINGSTEERING LINKAGE
SR−85
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE ENGINE UNDER COVER
Remove the 4 bolts.
2. REMOVE PITMAN ARM
(a) Remove the pitman arm set nut and spring washer.
(b) Using SST, disconnect the pitman arm from the cross
shaft.
SST 09628−62011
(c) Remove the cotter pin and nut.
(d) Using SST, disconnect the pitman arm from the relay rod.
SST 09611−22012
3. REMOVE LH AND RH TIE ROD ASSEMBLIE
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod assembly from the relay
rod.
SST 09628−62011
(c) Remove the cotter pin and nut.
(d) Using SST, disconnect the tie rod assembly from the
knuckle arm.
SST 09610−20012
4. REMOVE RH AND LH TIE ROD SUB−ASSEMBLIES,
TIE ROD END SUB−ASSEMBLIES, TIE RODS AND 2
CLAMPS
Remove the 2 bolts, washers and nuts.
5. REMOVE STEERING DAMPER
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the steering damper from the relay
rod.
SST 09611−22012
(c) Remove the bolt and nut.

Downloaded from www.Manualslib.com manuals search engine R08099
SST SR−86
− STEERINGSTEERING LINKAGE
1996 TOYOTA T100 (RM449U)
6. REMOVE IDLER ARM ASSEMBLY
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the idler arm from the relay rod.
SST 09610−20012
(c) Remove the 3 bolts, washers and nuts.

Downloaded from www.Manualslib.com manuals search engine SR088−02
R08100
AA = A’
B = B’ BB’ A’
Z03912
Front
Front
SR0262 SR1454
− STEERINGSTEERING LINKAGE
SR−87
1996 TOYOTA T100 (RM449U)
INSTALLATION
HINT:
When connecting the ball stud to the arm or rod, remove the
grease on the joint surfaces.
1. INSTALL IDLER ARM ASSEMBLY
(a) Install the 3 bolts, washers and nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
(b) Connect the idler arm to the relay rod.
(c) Install the nut and a new cotter pin.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
2. INSTALL STEERING DAMPER
(a) Torque the bolt and nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(b) Install the nut and a new cotter pin.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
3. INSTALL RH AND LH TIE ROD SUB−ASSEMBLIES,
TIE ROD END SUB−ASSEMBLIES, TIE ROD AND 2
CLAMPS
(a) Screw the tie rod end sub−assembly and tie rod sub−as-
sembly into the tie rod.
HINT:
The tie rod assembly length should be approximately 329.2 mm
(12.961 in.), and the remaining length of threads on both RH
and LH tie rod assemblies should be equal.
(b) Turn the tie rod end sub−assembly so that they cross at
about 90 degrees.
(c) After adjusting toe−in, torque the bolt.
(See page SA−10)
Torque: 22 N·m (225 kgf·cm, 16 ft·lbf)
4. INSTALL RH AND LH TIE ROD ASSEMBLIES
(a) Connect the tie rod assembly to the knuckle arm.
(b) Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
(c) Connect the tie rod assembly to the relay rod.
(d) Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine R04469
Alignment
Marks SR−88
− STEERINGSTEERING LINKAGE
1996 TOYOTA T100 (RM449U)
5. INSTALL PITMAN ARM
(a) Align the alignment marks on the pitman arm and the
cross shaft.
(b) Install the spring washer and pitman arm set nut.
Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
(c) Connect the pitman arm to the relay rod.
(d) Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
6. INSTALL ENGINE UNDER COVER
Tighten the 4 bolts.
7. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)

Downloaded from www.Manualslib.com manuals search engine BE01F−10
BE−2
− BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TOYOTA T100 (RM449U)
PROBLEM SYMPTOMS TABLE
The table below will be useful for you in troubleshooting these electrical problems. The most likely causes
of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and re-
place the part when it is found to be faulty.
USA:
HEADLIGHT AND TAILLIGHT SYSTEM
SymptomSuspect AreaSee page
Headlight does not light up
(Taillight is normal)
1. HEAD Fuse (Relay Block)
2. Light Control Switch
3. Headlight Dimmer Switch
4. Headlight BulbBE−14
BE−17
BE−17
BE−17
Headlight does not light up
(Taillight does not light up)
1. Light Control Switch
2. Headlight Dimmer Switch
3. Wire Harness
4. Headlight BulbBE−17
BE−17
−
−
Only one light comes on
1. HEAD Fuse (Relay Block)
2. Wire Harness
3. Headlight BulbBE−14
−
−
”Lo−Beam” does not light up
1. Headlight Control Relay
2. Headlight Dimmer Relay
3. Headlight Dimmer Switch
4. Wire Harness
5. Headlight BulbBE−17
BE−17
BE−17
−
−
”Hi−Beam” does not light up
1. Headlight Control Relay
2. Headlight Dimmer Relay
3. Headlight Dimmer Switch
4. Wire Harness
5. Headlight BulbBE−17
BE−17
BE−17
−
−
”Flash” does not light up
1. Headlight Control Relay
2. Headlight Dimmer Relay
3. Headlight Dimmer Switch
4. Wire Harness
5. Headlight BulbBE−17
BE−17
BE−17
−
−
Taillight does not light up
(Headlight does not light up)
1. TAIL Fuse (Junction Block No.1)
2. Light Control Switch
3. Wire Harness
4. Headlight BulbBE−17
BE−17
−
−
Taillight does not light up
(Headlight is normal)
1. TAIL Fuse (Junction Block No.1)
2. Light Control Switch
3. Taillight Control Relay
4. Wire Harness
5. Taillight BulbBE−14
BE−17
BE−17
−
−
Only one light goes out or does not light up1. Wire Harness
2. Taillight Bulb−
−
Rear Combination light does not light up
1. TAIL Fuse (Junction Block No.1)
2. Wire Harness
3. Taillight BulbBE−14
−
−
”Light−on warning system” does not operate.
1. Integration Relay
2. DOME Fuse (Relay Block)
3. GAUGE Fuse (Junction Block No.1)
4. Door Courtesy Switch
5. Wire HarnessBE−17
BE−14
BE−14
BE−25
−