1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine R04163
Matchmarks
SA0I3−01
R08285
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−139
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN HYPOID GEAR OIL
2. REMOVE REAR AXLE SHAFTS (See page SA−131)
3. REMOVE PROPELLER SHAFT
(2WD: See page PR−3)
(4WD: See page PR−11)
4. REMOVE DIFFERENTIAL CARRIER ASSEMBLY
(a) Remove the 10 nuts, washers and differential carrier as-
sembly.
Torque: 73 N·m (740 kgf·cm, 54 ft·lbf)
NOTICE:
Be careful not to damage the installation surface.
(b) Remove the gasket.

Downloaded from www.Manualslib.com manuals search engine SA259−01
W00493
30 mm
(1.18 in.)
R04321
R04322
R04323
R04463
SA−140
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
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: 0.09 mm (0.0035 in.)
Lateral runout: 0.09 mm (0.0035 in.)
If the runout is greater than the maximum, replace the compan-
ion flange.
2. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 in.)
3. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash:
2WD: 0.08 − 0.13 mm (0.0031 − 0.0051 in.)
4WD: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If the backlash is not within specification, adjust the side bear-
ing preload or repair if necessary.
HINT:
Measure from 3 or more places on the circumference of the ring
gear.
4. CHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−145)
5. CHECK SIDE GEAR BACKLASH
Using a dial indicator, measure the side gear backlash with
holding one pinion gear toward the case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the side
gear thrust washers of differential thickness.

Downloaded from www.Manualslib.com manuals search engine SA2349
SST
R11391SST
SA2348
SST
Z00641
SST
R04324
Matchmarks
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−141
1996 TOYOTA T100 (RM449U)
6. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake 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
7. REMOVE FRONT OIL SEAL
Using SST, remove the oil seal from the differential carrier.
SST 09308−10010
8. REMOVE FRONT BEARING AND BEARING SPECER
(a) Using SST, remove the bearing from the drive pinion.
SST 09556−22010
(b) Remove the 2 washers and bearing spacer. If the front
bearing is damaged or worn, replace the bearing.
9. REMOVE DIFFERENTIAL CASE
(a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 4 bolts and bearing cap.

Downloaded from www.Manualslib.com manuals search engine R04325
SST
R02482
SST
R04326
R04327
Matchmarks SA−142
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
(c) Using SST and a hammer, remove the 2 side bearing
plate washers.
SST 09504−22011
HINT:
Measure the plate washer and note down the thickness.
(d) Remove the differential case and bearing outer race from
the carrier.
HINT:
Tag the bearing outer races to show the location for reassem-
bling.
10. REMOVE DRIVE PINION FROM DIFFERENTIAL
CARRIER
11. REMOVE DRIVE PINION REAR BEARING
Using SST and a press, remove the bearing from the drive pin-
ion.
SST 09950−00020
HINT:
If the drive pinion or ring gear are damaged replace them as a
set.
12. REMOVE FRONT AND REAR BEARING OUTER
RACES
NOTICE:
Do not remove the outer races except when replacing the
bearings.
Using a brass bar and hammer, remove the 2 outer races and
adjusting washer from the carrier.
HINT:
Measure the adjusting washer and note down the thickness.
13. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 ring gear set bolts.
(c) Using a plastic hammer, tap on the ring gear to separate
it from the differential case.

Downloaded from www.Manualslib.com manuals search engine R04328
R12920
SST
SST
RA0997
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−143
1996 TOYOTA T100 (RM449U)
14. CHECK DIFFERENTIAL CASE RUNOUT
(a) Install the differential case in the differential carrier (See
page SA−145).
(b) Using a dial indicator, measure the differential case run-
out.
Maximum case runout: 0.04 mm (0.0016 in.)
(c) Remove the differential case.
15. REMOVE SIDE BEARINGS
Using SST, remove the 2 side bearings from the differential
case.
SST 09950−40010, 09950−60010 (09951−00450)
HINT:
Fix the claws of SST to the notch in the differential case.
16. DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove these parts from the differential case:
Pinion shaft
2 pinion gears
2 pinion gear thrust washers
2 side gears
2 side gear thrust washers

Downloaded from www.Manualslib.com manuals search engine R04330
SST
SA0I5−01
R04331
SST SA−144
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
REPLACEMENT
REPLACE COMPANION FLANGE DUST DEFLECTOR
(a) Using SST and a press, remove the dust deflector.
SST 09950−00020
(b) Using SST and a press, install a new dust deflector.
SST 09523−36010

Downloaded from www.Manualslib.com manuals search engine FA1121
SA0I6−02
FA1122
FA1123
FA1124
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−145
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the 2 proper thrust washers to the side gears.
HINT:
Refer to the table below to select thrust washers which will en-
sure that the backlash is within specifications.
Washer thickness
Thickness mm (in.)Thickness mm (in.)
1.50 (0.0590)1.75 (0.0689)
1.55 (0.0610)1.80 (0.0709)
1.60 (0.0630)1.85 (0.0728)
1.65 (0.0650)1.90 (0.0748)
1.70 (0.0669)−
(b) Install the 2 side gears with the thrust washers, pinion
gears, pinion gear thrust washers and pinion shaft.
HINT:
Align the holes of the differential case and pinion shaft.
(c) Using a dial indicator, measure the side gear backlash
with holding one pinion gear toward the case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within specification, replace the thrust
washers.
(d) Using a pin punch and hammer, install the straight pin
through the holes in the differential case and pinion shaft.
(e) Using a chisel and hammer, stake the out side of the dif-
ferential case pin hole.

Downloaded from www.Manualslib.com manuals search engine R04333
SST
SST
SA1143
Boiling Water
R04332
Matchmarks
R04334
R04335
SST SA−146
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
2. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 side bearings into the differ-
ential case.
SST 09506−35010, 09950−60010 (09951−00480),
09950−70010 (09951−07150)
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and
ring gear.
(b) Heat the ring gear to about 100°C (212°F) in boiling wa-
ter.
(c) Carefully take the ring gear out of the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(e) Align the matchmarks on the ring gear and differential
case.
(f) After the ring gear cools down enough, torque the set
bolts to which thread lock has been applied.
Thread lock:
Part No. 08833−00100, THREE BOND 1360K or equiv-
alent.
Torque: 125 N·m (1,270 kgf·cm, 92 ft·lbf)
4. INSPECT RING GEAR RUNOUT
(a) Install the differential case into the carrier and install the
plate washers to make sure the play in the bearing (See
page SA−57).
(b) Install bearing cap (See page SA−57).
(c) Using a dial indicator, measure the runout of ring gear.
Maximum runout: 0.05 mm (0.0020 in.)
5. INSTALL DRIVE PINION BEARING OUTER RACES
AND ADJUSTING WASHER
(a) Using SST, install a new front bearing outer race to the
carrier.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
(b) Using SST, install a new adjusting washer and install a
new rear bearing outer race to the carrier.
SST 09950−60020 (09951−00910),
09950−70010 (09951−07150)