1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine R15218
Intermediate Shaft
Assembly
PS Gear Assembly
 O−Ring
Return Tube
Return Hose
Pressure Feed Tube Mount Bracket  Cotter Pin
Grommet
Non−reusable part
Power steering fluid  O−Ring
90 (920, 67)
88 (900, 65)35 (360, 26)
88 (900, 65)
90 (920, 67)
88 (900, 65)
25 (250, 18)
*19 (195, 14)
13 (130, 9)
*10 (102, 7)
: Specified torque
N·m (kgf·cm, ft·lbf)
*For use with SST
SR07U−01
SR−54
− STEERINGPOWER STEERING GEAR (2WD)
1728 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING GEAR (2WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Z18926
Turn Pressure Tube
Dust Cover
Control Valve Housing
 Gasket
Control Valve Assembly
Steering Rack Stopper Rack End
Tie Rod EndCylinder End Rack Housing Cap Rack GuideRack Housing
Rack Guide
Spring Oil Seal
 Bearing
 Teflon Ring
 Bearing  Oil Seal  Oil Seal O−Ring
 O−Ring
 Rack Guide Spring
 Rack GuideCap Lock Nut
Spring Cap Bearing
 Self−Locking Nut
Rack Bushing O−Ring  Oil Seal  Wire  Claw Wash
 O−Ring Clip
 Teflon Ring Lock Nut
Rack Boot
Clamp
Non−reusable part
Precoated part
Molybdenum disulfide lithium base grease Power steering fluid 

18 (185, 13)
13 (130, 9)
*10 (102, 7) 13 (130, 9)
*10 (102, 7)
: Specified torque
N·m (kgf·cm, ft·lbf)
*for use with SST56 (570, 41)
60 (700, 51)
*51 (521, 38)
25 (250, 18)
69 (700, 51)
83 (850, 62)
*61 (618, 45)
− STEERINGPOWER STEERING GEAR (2WD)
SR−55
1729 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine SR07V−01
R04277
SST
R15246
SST SR−56
− STEERINGPOWER STEERING GEAR (2WD)
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 RH AND LH TIE ROD ENDS
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end from the knuckle
arm.
SST 09610−20012
5. DISCONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−13)
6. DISCONNECT RETURN HOSE
7. DISCONNECT PRESSURE FEED TUBE AND REMOVE
RETURN TUBE
(a) Using SST, disconnect the pressure feed tube and re-
move the return tube.
SST 09631−22020
(b) Remove the O−ring from the tube.
8. REMOVE MOUNT BRACKET AND GROMMET
(a) Remove the 2 bolts.
(b) Remove the mount bracket and grommet from the PS
gear assembly.
9. REMOVE PS GEAR ASSEMBLY
Remove the 2 gear assembly set bolts and nut.

Downloaded from www.Manualslib.com manuals search engine SR07W−01
R15215
SST
R04580
SST
R00429
Matchmark
R12979
R04582
− STEERINGPOWER STEERING GEAR (2WD)
SR−57
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE 2 TURN PRESSURE TUBES
(a) Remove the bolt and clamp plate.
(b) Using SST, remove the tube.
SST 09633−00020
(c) Remove the 2 O−rings from the tube.
2. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612−00012
3. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS
Place matchmarks on the tie rod end and rack end.
4. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Using a screwdriver, loosen the clamp.
NOTICE:
Be careful not to damage the boot.
Mark the RH and LH boots.
5. REMOVE RH AND LH RACK ENDS AND CLAW
WASHERS
(a) Using a chisel and a hammer, unstake the washer.
NOTICE:
Avoid any impact to the steering rack.

Downloaded from www.Manualslib.com manuals search engine Z14296
SST
R11782SST
R04590
SST
R04593
Matchmarks SR−58
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
(b) Using a spanner to hold the steering rack steady, and us-
ing SST, remove the rack end.
SST 09922−10010
NOTICE:
Use SST 09922−10010 in the direction shown in the il-
lustration.
Mark the RH and LH rack ends.
6. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922−10010
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
7. REMOVE RACK GUIDE SPRING CAP
Using a hexagon wrench (21 mm), remove the cap.
8. REMOVE RACK GUIDE SPRING AND RACK GUIDE
9. REMOVE RACK HOUSING CAP
10. REMOVE SELF−LOCKING NUT
Using SST to stop the control valve assembly rotating, remove
the nut.
SST 09616−00010
11. REMOVE DUST COVER
12. REMOVE CONTROL VALVE HOUSING WITH
CONTROL VALVE ASSEMBLY
(a) Place matchmarks on the valve housing and rack hous-
ing.
(b) Remove the 2 bolts.
(c) Pull out the control valve assembly with the valve hous-
ing.
(d) Remove the gasket from the rack housing.

Downloaded from www.Manualslib.com manuals search engine R13023
Vinyl Tape
R04594
SSTWire
R15247
SST
− STEERINGPOWER STEERING GEAR (2WD)
SR−59
1996 TOYOTA T100 (RM449U)
13. REMOVE CONTROL VALVE ASSEMBLY
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the valve shaft.
(b) Using a plastic hammer, tap out the valve with the oil seal
from the control valve housing.
NOTICE:
Be careful not to damage the oil seal lip.
(c) Remove the oil seal from the valve assembly.
14. REMOVE CYLINDER END STOPPER
(a) Using SST, turn the stopper clockwise until the wire end
comes out.
SST 09631−10021
(b) Using SST, turn the stopper counterclockwise, and re-
move the wire.
SST 09631−10021
15. REMOVE STEERING RACK AND RACK BUSHING
(a) Using a brass bar and a hammer, tap out the rack with the
rack busing.
(b) Remove the O−ring from the bushing.
16. REMOVE OIL SEAL
Using SST and a brass bar, drive out the oil seal from the rack
housing.
SST 09623−30011

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R10072
Dial Indicator
R14216
SSTOil Seal SST
Bearing
W03367
SST
SST
Oil Seal
SST
R14218
SST
SST
Bearing
Oil Seal
SST
Z14493Bearing SR−60
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT STEERING RACK
(a) Using a dial indicator, check the rack for runout and for
teeth wear or damage.
Maximum runout: 0.03 (0.0012 in.)
(b) Check the back surface for wear or damage.
2. IF NECESSARY, REPLACE OIL SEAL AND BEARING
(a) Using SST, tap out the oil seal and bearing from the con-
trol valve housing.
SST 09950−60010 (09951−00250),
09950−70010 (09951−07150)
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST, press in the oil seal.
SST 09950−60010 (09951−00180, 09951−00320,
09952−06010), 09950−70010 (09951−07200)
NOTICE:
Make sure to install the oil seal facing the correct direction.
(d) Using SST, press in a new bearing.
SST 09950−60010 (09951−00180, 09951−00340,
09952−06010), 09950−70010 (09951−07200)
3. IF NECESSARY, REPLACE 2 BEARINGS
(a) Using a brass bar, drive out the bearing from the rack
housing.

Downloaded from www.Manualslib.com manuals search engine Z14494
SST Bearing
R15250
SST
SSTBearingSST
R14219
SSTSST
Bearing
R15249
SST
Oil Seal
R14003
Press
Oil Seal
SSTSST
− STEERINGPOWER STEERING GEAR (2WD)
SR−61
1996 TOYOTA T100 (RM449U)
(b) Using SST, remove the bearing from the rack housing.
SST 09612−24014 (09613−22011)
NOTICE:
Be careful not to damage the rack housing.
(c) Coat a new bearing with molybdenum disulfide lithunm
base grease.
(d) Using SST, press in the bearing.
SST 09950−60010 (09951−00250, 09951−00310,
09952−06010), 09950−70010 (09951−07150)
(e) Coat a new bearing with molybdenum disulfide lithunm
base grease.
(f) Using SST, press in the bearing.
SST 09950−60010 (09951−00310),
09950−70010 (09951−07150)
4. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, remove the oil seal from the rack bushing.
SST 09236−00101 (09237−00010),
09612−65014 (09612−01060)
NOTICE:
As shown, from the opposite side of SST confirm that
its claw is firmly caught on the bushing.
Be careful not to damage the bushing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST, press in the oil seal to the rack bushing.
SST 09950−60010 (09951−00260, 09951−00410,
09952−06010)
NOTICE:
Make sure to install the oil seal facing the correct direction.