1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine R04620
R04621
28−8°
2−5 mm
(0.08−0.20in.)
R15216
SST
Fulcrum
Length SR−70
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
17. INSTALL RH AND LH RACK BOOTS, CLAMPS AND
CLIPS
(a) Make sure that the tube hole is not clogged with grease.
HINT:
If the tube hole is clogged, the pressure inside the boot will
change after it is assembled and the steering wheel turned.
(b) Install the boot.
NOTICE:
Be careful not to damage or twist the boot.
(c) Tighten the clamp and clip, as shown in the illustration.
18. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe−in, torque the lock nut (See page
SA−7).
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
19. INSTALL 2 TURN PRESSURE TUBES
(a) Coat 2 new O−rings with power steering fluid and install
them to the tube.
(b) Using SST, install and torque the tube.
SST 09633−00020
Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
(c) Install the clamp plate with the bolt.

Downloaded from www.Manualslib.com manuals search engine SR07Z−01
R15251
SST
Fulcum Length
− STEERINGPOWER STEERING GEAR (2WD)
SR−71
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
Torque the 2 gear assembly set bolts and nut.
2. INSTALL MOUNT BRACKET AND GROMMET
(a) Install the grommet and mount bracket to the PS gear as-
sembly.
(b) Torque the 2 bolts.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
3. CONNECT PRESSURE FEED TUBE AND INSTALL
RETRUN TUBE
(a) Coat a new O−ring with power steering fluid and install it
to the tube.
(b) Using SST, connect the pressure feed tube and install the
return tube.
SST 09631−22020
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT RETURN HOSE
5. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
6. CONNECT RH AND LH TIE ROD ENDS
Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
7. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
8. CENTER SPIRAL CABLE
(See page SR−20)
9. 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.
10. BLEED POWER STEERING SYSTEM
(See page SR−4)
11. CHECK STEERING WHEEL CENTER POINT
12. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
13. INSTALL STEERING WHEEL PAD
(See page SR−20)
14. CHECK FRONT WHEEL ALIGNMENT
(See page SA−7)

Downloaded from www.Manualslib.com manuals search engine R15457
Return Tube
Intermediate Shaft Assembly
Pressure Feed Tube
PS Gear Assembly
Pitman Arm Sub−Assembly
With Relay Rod
Spring Washer 44 (450, 33)
*36 (365, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
35 (360, 26)
44 (450, 33)
*36 (365, 26)
142 (1450, 105)
177 (1800, 130)
SR080−01
SR−72
− STEERINGPOWER STEERING GEAR (4WD)
1746 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING GEAR (4WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Z18651
 Washer
 O−Ring
 No.1 Lock Nut Side Cover No.1 Hose Support Bracket Adjusting Screw Lock Nut
Sector Shaft Adjusting Screw
Cross Shaft
Power Piston
Plunger Guide Nut
Compression Spring
Power Piston Plunger
Power Piston Plunger Guide
Power Steering Gear HousingNeedle Roller Bearing
 Union Seat
 O−Ring
 Teflon RingWorm Gear Valve
Body Assembly
Metal Spacer
 Snap ring
Non−reusable part
Power Steering fluid
Molybdenum disulfide lithium base grease  O−Ring
 O−Ring
 Teflon Ring
 Oil Seal
61 (620, 45)
61 (620, 45)
: Specified torque
N·m (kgf·cm, ft·lbf)
46 (470, 34)
20 (205, 15)
− STEERINGPOWER STEERING GEAR (4WD)
SR−73
1747 Author: Date:
1996 TOYOTA T100 (RM449U)

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 SR082−01
R01279
SST
R01292
R01293
Z14397
Hexagon
Wrench
R15243
SST
− STEERINGPOWER STEERING GEAR (4WD)
SR−75
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtightn it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Mount the gear assembly on SST and clamp SST in a vise.
SST 09630−00014 (09631−00142)
2. REMOVE ADJUSTING SCREW LOCK NUT AND SEAL
WASHER
3. REMOVE SIDE COVER
(a) Remove the 4 bolts and No.1 hose support bracket.
(b) Using a screwdriver, turn the sector shaft adjusting screw
clockwise until the cover comes off.
(c) Remove the O−ring from the cover.
4. REMOVE SECTOR SHAFT
Using a plastic hammer, tap on the sector shaft end and pull out
the shaft.
5. REMOVE POWER PISTON PLUNGER GUIDE NUT,
COMPRESSION SPRING, POWER PISTON PLUNGER
AND POWER PISTON PLUNGER GUIDE
(a) Using a hexagon wrench (10 mm), remove the plunger
guide nut.
(b) Remove the O−ring from the plunger guide nut.
6. REMOVE WORM GEAR VALVE BODY ASSEMBLY
(a) Remove the 4 bolts.
(b) Using SST, turn the valve body shaft clockwise with hold-
ing the power piston nut by your finger so it cannot move.
SST 09616−00010
(c) Pull out the valve body assembly.
NOTICE:
Ensure that the power piston nut does not come off the
worm shaft.
(d) Remove the 2 O−rings from the gear housing.

Downloaded from www.Manualslib.com manuals search engine SR083−01
Z14503
Dial Indicator
30 mm
(1.18 in.)
Z14504
Dial
Indicator
R01297
R01283
SST
Z06211 SR3019 SR3020
SR−76
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT BALL CLEARANCE
Using a dial indicator, check the ball clearance. Move the power
piston nut up and down.
Maximum clearance: 0.15 mm (0.0059 in.)
2. INSPECT SECTOR SHAFT ADJUSTING SCREW
THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.03 − 0.05 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.05 mm (0.0020 in.)
3. IF NECESSARY, ADJUST SECTOR SHAFT
ADJUSTING SCREW THRUST CLEARANCE
(a) Using a chisel and hammer, unstake the No.1 lock nut.
(b) Using SST, remove the No.1 lock nut.
SST 09630−00014 (09631−00051)
(c) Using a screwdriver, adjust the adjusting screw for the
correct thrust clearance.
(d) Tighten a new lock nut.
(e) Stake the lock nut.
4. IF NECESSARY, REPLACE 2 NEEDLE ROLLER
BEARINGS
(a) Using a screwdriver, pry out the oil seal from the gear
housing.
(b) Using snap ring pliers, remove the snap ring from the gear
housing.
(c) Remove the metal spacer, teflon ring and O−ring from the
gear housing.

Downloaded from www.Manualslib.com manuals search engine Z14505
SST
Bearing
R14227
SST
SST
Bearing
R14228
Bearing SST 23.1 mm
(0.909 in.)SST
SST SST
R14324
SST
Bearing 89.0 mm
(3,504 in.)
SST
SST SST
− STEERINGPOWER STEERING GEAR (4WD)
SR−77
1996 TOYOTA T100 (RM449U)
(d) Using SST, remove the bearing from the gear housing.
SST 09612−65014 (09612−01030)
(e) Using SST, press out the bearing from the gear housing.
SST 09950−60010 (09951−00360, 09951−00420,
09952−06010), 09950−70010 (09951−07200)
(f) Coat a new bearing with molybdenum disulfide lithium
base grease.
(g) Using SST, press in the bearing, as shown in the illustra-
tion.
SST 09950−60010 (09951−00360, 09951−00420,
09952−06010), 09950−70010 (09951−07200)
(h) Coat a new bearing with molybdenum disulfide lithium
base grease.
(i) Using SST, press in the bearing, as shown in the illustra-
tion.
SST 09950−60010 (09951−00360, 09951−00420,
09952−06010), 09950−70010 (09951−07200)
(j) Coat a new O−ring and metal spacer with power steering
fluid.
(k) Install the O−ring and metal spacer.
(l) Using snap ring pliers, install a new snap ring.
(m) Coat a new teflon ring with power steering fluid.
(n) Form the teflon ring into a heart shape and install it by
hand.