1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine SA0G3−02
Z00638
SST
B4056 B4057
R11389
SST
SA0505
SST
SA0507
SST
Z03906
SST
1.5 mm (0.059 in.)
Drive in Depth
− SUSPENSION AND AXLEFRONT DIFFERENTIAL REAR OIL SEAL (4WD)
SA−43
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER
2. REMOVE FRONT PROPELLER SHAFT
(See page PR−11)
3. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, loosen the staked part of the
nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
(c) Using SST, remove the companion flange.
SST 09950−30010
4. REMOVE OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal.
SST 09308−10010
(b) Remove the oil slinger.
5. REMOVE REAR BEARING AND BEARING SPACER
(a) Using SST, remove the rear bearing from the drive pinion.
SST 09556−22010
(b) Remove the bearing spacer.
6. INSTALL BEARING SPACER, REAR BEARING AND
OIL SLINGER
(a) Install a new bearing spacer.
(b) Install the rear bearing.
(c) Install the oil slinger.
7. INSTALL OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09554−30011
Oil seal drive in depth: 1.5 mm (0.059 in.)
(b) Apply MP grease to the oil seal lip.

Downloaded from www.Manualslib.com manuals search engine R12169
SST
FA1083
SST
R04344
Less than 5 mm (0.20 in.) SA−44
− SUSPENSION AND AXLEFRONT DIFFERENTIAL REAR OIL SEAL (4WD)
1996 TOYOTA T100 (RM449U)
8. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange on the drive pin-
ion.
SST 09950−30010
(b) Apply light coat of hypoid gear oil on threads of a new
companion flange nut.
(c) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
9. ADJUST DRIVE PINION PRELOAD
(See page SA−57)
10. STAKE DRIVE PINION NUT
11. INSTALL FRONT PROPELLER SHAFT
(See page PR−16)
12. FILL DIFFERENTIAL WITH HYPOID GEAR OIL
Torque:
Drain plug: 49 N·m (500 kgf·cm, 36 ft·lbf)
Filler plug: 39 N·m (400 kgf·cm, 29 ft·lbf)
Oil type: Hypoid gear oil API GL−5
Recommended oil viscosity: SAE 75W−90
Capacity: 1.86 liters (1.97 US qts, 1.64 lmp. qts)
13. INSTALL ENGINE UNDER COVER

Downloaded from www.Manualslib.com manuals search engine SA0G4−03
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−45
1484 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT DIFFERENTIAL CARRIER (4WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine SA−46
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1485 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine SA0G5−01
R04298
Matchmarks
R04533
FA0858
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−47
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE ENGINE UNDER COVER AND DRAIN HYPO-
ID GEAR OIL
2. REMOVE FRONT PROPELLER SHAFT
(See page PR−11)
3. REMOVE DRIVE SHAFT NUTS
(a) Place matchmarks on the drive shaft and side gear shaft,
and remove the 6 nuts holding the drive shaft and side
gear shaft.
Torque: 83 N·m (845 kgf·cm, 61 ft·lbf)
(b) Employ the same manner described above to the other
side.
4. DISCONNECT VACUUM HOSES AND 4WD INDICA-
TOR SWITCH CONNECTOR
5. REMOVE CROSSMEMBER
Remove the 4 nuts, washers, bolts and crossmember.
Torque: 126 N·m (1,280 kgf·cm, 93 ft·lbf)
6. REMOVE DIFFERENTIAL FRONT MOUNTING BOLT
AND NUT
Torque: 147 N·m (1,500 kgf·cm, 108 ft·lbf)
7. REMOVE FRONT DIFFERENTIAL ASSEMBLY
(a) Support the front differential with a jack.
(b) Remove the left and right rear mounting bolts.
Torque: 167 N·m (1,700 kgf·cm, 123 ft·lbf)
(c) Lower the jack and remove the front differential assembly.

Downloaded from www.Manualslib.com manuals search engine W00493
30 mm
(1.18 in.)
SA258−01
SA2352
W00400
SA0344
SA−48
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the runout of the companion
flange vertical and lateral.
Maximum
Vertical runout: 0.10 mm (0.0039 in.)
Lateral runout: 0.10 mm (0.0039 in.)
2. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the drive pinion preload using
the backlash of the drive pinion and ring gear.
Preload (at starting):
0.6 − 1.0 N·m (6 − 10 kgf·cm, 5.2 − 8.7 in.·lbf)
If the runout is greater than the maximum, replace the compan-
ion flange.
3. CHECK TOTAL PRELOAD
Using a torque wrench, measure the total preload.
Total preload (at starting):
Drive pinion preload plus
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
If necessary, disassemble and inspect the differential.
4. REMOVE A.D.D. ACTUATOR
(a) Remove the 4 bolts.
(b) Using a hammer handle, remove the actuator.
5. REMOVE DIFFERENTIAL CARRIER COVER
Remove the 8 bolts and tap out the cover with a plastic hammer.
6. CHECK SIDE GEAR BACKLASH
Using a dial indicator, measure the side gear backlash with
holding one pinion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is out of specification, install the correct thrust
washers (See page SA−57).

Downloaded from www.Manualslib.com manuals search engine SA0346
SA0349
SA0337
SST
SA0352
SST
R11390
SST
SST
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−49
1996 TOYOTA T100 (RM449U)
7. REMOVE LH SIDE GEAR SHAFT WITH TUBE
(a) Using a torx socket (E14), remove the 4 torx bolts.
(b) Using a plastic hammer, tap on the tube to remove it.
(c) Remove the sleeve.
(d) Remove the O−ring from the tube.
8. REMOVE CLUTCH CASE
(a) Using a torx socket (E14), remove the 2 torx bolts.
(b) Using a plastic hammer, tap on the clutch case to remove
it.
9. REMOVE RH SIDE GEAR SHAFT
Using SST, remove the side gear shaft.
SST 09910−00015 (09911−00011, 09912−00010,
09914−00011)
10. REMOVE RH SIDE GEAR SHAFT OIL SEAL
Using SST, remove the right side gear shaft oil seal.
SST 09308−00010
11. REMOVE INTERMEDIATE SHAFT
Using SST, remove the intermediate shaft.
SST 09350−20015 (09369−20040), 09950−40010

Downloaded from www.Manualslib.com manuals search engine Z03854
Z03853
Z03852
SA2349
SST
R11391SST SA−50
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
12. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace the ring gear
and drive pinion as a set.
13. CHECK RING GEAR BACKLASH
(a) Fix the dial indicator on the tooth surface at a 90° angle.
(b) Using a dial indicator, with holding the drive pinion flange
and measure the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0070 in.)
If the backlash is not within the specification, adjust the ring
gear backlash.
HINT:
Measure from 3 or more places on the circumference of the ring
gear.
14. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−57)
15. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake the nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
(c) Using SST, remove the companion flange.
SST 09950−30010