1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine SA0FY−01
R04298
Matchmarks
− SUSPENSION AND AXLEFRONT DRIVE SHAFT (4WD)
SA−37
1996 TOYOTA T100 (RM449U)
REMOVAL
1. LOOSEN NUTS HOLDING FRONT DRIVE SHAFT
(a) Place matchmarks on the inboard joint tulip and side gear
shaft.
(b) Loosen the 6 nuts, with depressing the brake pedal.
Torque: 83 N·m (845 kgf·cm, 61 ft·lbf)
2. REMOVE FLANGE (See page SA−23)
3. REMOVE SNAP RING AND SPACER
Using a snap ring expander, remove the snap ring from the
drive shaft.
4. REMOVE FRONT DRIVE SHAFT
First pull the drive shaft inboard joint tulip from the side gear
shaft and then pull it out from the steering knuckle.
NOTICE:
Be careful not to damage the oil seal and boot.

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 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 SA0360
SST
SA0334SST
SA0398
SA0399
SST
SA0335
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−55
1996 TOYOTA T100 (RM449U)
(7) Using SST and a press, install a new bearing.
SST 09316−60011 (09316−00041)
(8) Using a snap ring expander, install a new snap ring.
(d) Replace the LH side oil seal.
(1) Using SST, remove the side oil seal.
SST 09308−00010
(2) With the oil seal lip facing upward, use press and
plate to press in a new oil seal until its end is flush
with the surface of the tube.
(3) Using SST and a press, install the oil seal.
SST 09554−14010
Oil seal drive in depth: 2.5 mm (0.098 in.)
(4) Coat the lip of oil seal with MP grease.
(e) Install the LH side gear shaft to the tube.
(1) Install the side gear shaft into the tube.
(2) Torque the 3 bearing retainer bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(f) Install the clutch hub.
(1) Install the clutch hub to the shaft.
(2) Using a snap ring expander, install a new snap ring.

Downloaded from www.Manualslib.com manuals search engine R04467
SST
SA0366
SA−56
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
(g) Repalce the RH side gear shaft dust cover.
(1) Using a screwdriver and hammer, remove the dust
cover.
(2) Using SST and a press, install a new dust cover.
SST 09710−30055
3. REPLACE A.D.D. ACTUATOR, IF NECESSARY
(a) Remove the A.D.D. indicator switch.
(b) Remove the sleeve fork pin.
(1) Using a hexagon wrench, remove the screw plug.
(2) Using a pin punch and hammer, remove the pin
through the hole of clutch case cover.
(c) Seperate A.D.D. actuator from the clutch case cover and
remove the sleeve fork.
(1) Using a hexagon wrench, remove the screw plug.
(2) Remove the spring seat, spring and steel ball.
(3) Remove the 2 bolts and actuator from the clutch
case cover.
(4) Separate the actuator from the clutch case cover
and remove the sleeve fork.
(5) Remove the O−ring from the actuator.
(d) Install the sleeve fork and A.D.D. actuator into the clutch
case cover.
(1) Install the new O−ring to the actuator.
(2) Coat the O−ring with MP grease.
(3) Place the sleeve fork and install the actuator to the
clutch case cover.
(4) Torque the 2 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(5) Install the steel ball, spring and spring seat.
(6) Coat the threads of screw plug with FIPG.
FIPG:
Part No.08826−00090, THREE BOND 1281 or equiva-
lent
(7) Using a hexagon wrench, install the screw plug.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(e) Install the sleeve fork pin.
(1) Using a pin punch and hammer, install the pin
through the hole of clutch case cover.
(2) Using a hexagon wrench, install the screw plug.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine FA1124
SA2160
Boiling Water
Z02483 FA1128
FA1129
SA1395
SST
SST SA−58
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
2. INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL
CASE
(a) Using a pin punch and hammer, install the straight pin
through the differential case and hole of the pinion shaft.
(b) Using a chisel and hammer, stake the out side of the dif-
ferential case pin hole.
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.
HINT:
Align the matchmarks on the ring gear and differential case.
(e) Temporarily install 5 new lock plates and 10 bolts so that
the bolt holes in the ring gear and differential case are not
misaligned.
(f) After the ring gear has cooled sufficiently, torque the 10
ring gear set bolts.
Torque: 97 N·m (985 kgf·cm, 71 ft·lbf)
(g) Using a chisel and hammer, stake the 5 lock plates.
HINT:
Stake the claw so that it is flush with the flat surface of the bolt.
For the claw contacting the protruding portion of the bolt, stake
only the half of it on the tightening side.
4. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 bearings into the differential
case.
SST 09226−10010, 09550−10012 (09558−10010)

Downloaded from www.Manualslib.com manuals search engine SA2352
FA0743
FA0744
FA0746
FA0743
SA−60
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
(e) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing:
1.2 − 1.9 N·m (12 − 19 kgf·cm, 10.4 − 16.5 in.·lbf)
Reused bearing:
0.6 − 1.0 N·m (6 − 10 kgf·cm, 5.2 − 8.7 in.·lbf)
9. INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL
CARRIER
(a) Place the 2 bearing outer races on their respective bear-
ings. Check that the left and right outer races are not inter-
changed.
(b) Install the differential case in the differential carrier.
10. ADJUST RING GEAR BACKLASH
(a) Only install the plate washer on the ring gear back side.
HINT:
Make sure that the ring gear has backlash.
(b) Tap on the ring gear with a plastic hammer so that the
washer fit to the bearing.
(c) Using a dial indicator, measure the side gear backlash
with holding one pinion gear toward the differential case.
Backlash (reference): 0.13 mm (0.0051 in.)
(d) Select a plate washer for back side ring gear, using the
backlash as reference (See page SA−57).