1996 TOYOTA T100 wheel alignment

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

Downloaded from www.Manualslib.com manuals search engine R12919
R12268F01731
A
B
C
D Front
Rear
SA0FF−02
Z03382
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT (2WD)
SA−7
1446 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT WHEEL ALIGNMENT (2WD)
INSPECTION
HINT:
For the vehicle height of non−loaded vehidles for each model
and alighment standed values, refer to page SA−11 9.
1. MEASURE VEHICLE HEIGHT
Vehicle height: See page SS−58
Front: A − B = 74.0 mm (2.913 in.)
Rear: C − D = Standed cab
0.5 ton: 122.0 mm (4.803 in.)
1.0 ton: 107.0 mm (4.213 in.)
Extre cab: 115.5 mm (4.547 in.)
Measuring points:
A: Steering knuckle height measured at its center on
the outer edge.
B: Lower suspension arm front adjusting bolt height
measured at its center.
C: Rear axle shaft height measured at its center.
D: Rear leaf spring front bushing height measured at
its center.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to specification.
If the vehicle height is not standard, try to adjust it by pushing
down on or lifting the body.
2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR
ONTO WHEEL ALIGNMENT TESTER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
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
If the steering axis inclination is not as specified, after camber
and caster have correctly adjusted, recheck the steering
knuckle front wheel for bearing or looseness.

Downloaded from www.Manualslib.com manuals search engine SA3213
A
FrontB
C D
FA0014R05239F01733
R04256
R04257
SA−8
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT (2WD)
1447 Author: Date:
1996 TOYOTA T100 (RM449U)
4. INSPECT TOE−IN
To e−in (total)
STD cabA + B: 0° ± 12’ (0° ± 0.2°)
C − D: 0 ± 2 mm (0 ± 0.08 in.)
Extra cab
P215/75 R15A + B: 0°22’ ± 12’ (−0.36° ± 0.2°)
C − D: −4.7 ± 2 mm (0.18 ± 0.08 in.)
Extra cab
P235/75 R15A + B: 0°22’ ± 12’ (0.36° ± 0.2°)
C − D: −4.9 ± 2 mm (0.19 ± 0.08 in.)
If the toe−in is not within the specification, adjust the rack end.
5. ADJUST CAMBER AND CASTER
HINT:
Try to adjust the camber and caster to center value.
If camber or caster is not within the specification, adjust by ad-
ding or removing shims on the upper suspension arm.
Shim thickness
4.0 mm (0.157 in.)1.6 mm (0.063 in.)1.2 mm (0.047 in.)
HINT:
If the steering axis inclination is not as specified after camber
and caster have been correctly adjusted, recheck the steering
knuckle and front wheel for distortion or looseness.
NOTICE:
Adjust the shim thickness to 7 mm (+4, −3), and adjust the
difference between the front and rear of the upper suspen-
sion arm shaft to within 4 mm.
If this adjustment is not possible, adjust the strut bar bush
set nut.
6. ADJUST TOE−IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an amount to adjust the
toe−in.
HINT:
Try to adjust the toe−in to the center value.
Make sure that the length of the left and right rack ends
are the same.
Rack end difference: 3.0 mm (0.118 in.) or less
(d) Tighten the tie rod end lock nut.
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
(e) Place the boot on the seat and install the clip.
HINT:
Make sure that the boots are not twisted.

Downloaded from www.Manualslib.com manuals search engine FA0018
A
Front BAB
A: Inside
B: Outside
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT (2WD)
SA−9
1448 Author: Date:
1996 TOYOTA T100 (RM449U)
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully, and measure the turning angle.
ItemInside wheelOutside wheel

STD cab 0.5 ton
Left−right error40°42’ ± 2°
(40.7° ± 2°)
30’(0.5°)34°23’
(34.38°)
STD cab 1.0 ton
Left−right error39°55’ ± 2°
(39.92° ± 2°)
30’(0.5°)34°37’
(34.67°)
Extra cab
Left−right error40°10’ ± 2°
(40.17’ ± 2°)
30’(0.5°)34°25’
(34.47°)
If the wheel angle differ from the standard specifications, check
to see if the lengths of the left and right tie rods are the same.
HINT:
If the tie rods lengths are not equal, the wheel angle cannot be
adjusted properly.
Reinspect the toe−in after adjusting the tie rods lengths.

Downloaded from www.Manualslib.com manuals search engine FA0442R12257F01732
A
B
CD Front
Rear
Z03382
SA0FG−02
SA−10
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT (4WD)
1449 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT WHEEL ALIGNMENT (4WD)
INSPECTION
HINT:
For the vehicle height of non−loaded vehicles for each model
and alignment standed values, refer to page SA−121.
1. MEASURE VEHICLE HEIGHT
Vehicle height:
Front: A − B = 58.0 mm (2.283 in.)
Rear: C − B = STD cab: 23.0 mm (0.906 in.)
Extra cab: 28.0 mm (1.102 in.)
Measuring points:
A: Drive shaft height measured at its center on the
outer edge.
B: Lower suspension arm front adjusting bolt height
measured at its center.
C: Rear leaf spring front bushing height measured at
its center.
D: Rear axle shaft height measured at its center.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to specification.
If the vehicle height is not standard, try to adjust it by pushing
down on or lifting the body.
2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR
ONTO WHEEL ALIGNMENT TESTER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
STD cab
Camber
Left−right error0°45’ ± 45’ (0.75° ± 0.75°)
45’ (0.75°) or less
Caster
Left−right error1°30’ ± 45’ (1.5° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error11°50’ ± 45’ (11.83° ± 0.75°)
45’ (0.75°) or less
Extra cab
Camber
Left−right error0°45’ ± 45’ (0.75° ± 0.75°)
45’ (0.75°) or less
Caster
Left−right error1°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
If the steering axis inclination is not as specified, after camber
and caster have correctly adjusted, recheck the steering
knuckle front wheel for bearing or looseness.

Downloaded from www.Manualslib.com manuals search engine SA3213
Front AB
D
C
FA0829FA0828F01734
Decrease
Increase
Decrease Increase Front Adjusting Cam
Rear Adjusting Cam
R08116
FA0017
Front
A = B AB
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT (4WD)
SA−11
1450 Author: Date:
1996 TOYOTA T100 (RM449U)
4. INSPECT TOE−IN
To e−in (total)
0.5 tonA + B: 0°05’ ± 12’ (0.08° ± 0.2°)
C − D: 1.0 ± 2 mm (0.04 ± 0.08 in.)
Extra cab
P235/75 R15A + B: −0°08’ ± 12’ (−0.14° ± 0.2°)
C − D: −1.9 ± 2 mm (0.07 ± 0.08 in.)
Extra cab
31 x 10.5 R15A + B: −0°08’ ± 12’ (−0.14° ± 0.2°)
C − D: −2.0 ± 2 mm (0.08 ± 0.08 in.)
If the toe−in is not within specification, adjust the tie rod end.
5. ADJUST CAMBER AND CASTER
(a) Loosen the front and/or rear adjusting cam nuts.
(b) Adjust the camber and caster by front and/or rear adjust-
ing cams (See adjustment chart).
HINT:
Try to adjust the camber and caster to the center value.
(c) Torque the front and/or rear adjusting cam nuts.
Torque: 226 N·m (2,300 kgf·cm, 166 ft·lbf)
6. ADJUST TOE−IN
(a) Loosen the clamp bolts and nuts.
(b) Adjust toe−in by turning the left and right tie rod tubes an
equal amount.
HINT:
Try to adjust the toe−in to the center value.
Make sure that the length of the left and right tie rods end
is equal.

Downloaded from www.Manualslib.com manuals search engine FA0927
Front
FA0018
Front
A: Inside
B: Outside ABBA
R08117
SA−12
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT (4WD)
1451 Author: Date:
1996 TOYOTA T100 (RM449U)
(c) Torque the tie rod clamp bolt.
Torque: 22 N·m (225 kgf·cm, 16 ft·lbf)
HINT:
Face the clamp bolt toward the front of the vehicle.
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully, and measure the turning angle.
ItemInside wheelOutside wheel

STD cab32°01’ ± 2°
(32.02° ± 2°)30°30’
(30.5°)
Extra cab32°14’ ± 2°
(33.23° ± 2°)30°30’
(30.5°)
If maximum steering angles differ from standard value, adjust
the wheel angle with the knuckle stopper bolts.
Torque: 47 N·m (480 kgf·cm, 35 ft·lbf)
If the wheel angle still cannot be adjusted within limits, inspect
and replace damaged or worn steering parts.
8. HOW TO READ ADJUSTMENT CHART
(a) Mark on the graph the measurements taken from the ve-
hicle.
Example:
Camber 0°40’ (0.67°)
Caster 0°35’ (0.58°)
(b) As shown in the chart, read from the graph the amounts
by which the from and/or rear cams are to be adjusted.
Amount to turn adjusting cam (by graduation):
Front cam −(Shorter) 1.8
Rear cam +(Longer) 3.1