Page 1532 of 2062
Downloaded from www.Manualslib.com manuals search engine Z03863
Plate
Washer
Z03848
Plate Washer
Plate Washer
Z03852
SA−62
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
11. ADJUST SIDE BEARING PRELOAD
(a) Remove the ring gear teeth side plate washer and mea-
sure the thickness.
(b) Using the backlash as a reference, install a new washer
of 0.06 − 0.09 mm (0.0024 − 0.0035 in.) thicker than the
washer removed.
HINT:
Select a washer which can be pressed in 2/3 of the way with
your finger.
(c) Using a plastic hammer, install the plate washer.
(d) Recheck the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0070 in.)
(e) If not within specification, adjust by either increasing or
decreasing the thickness of washers on both sides by an
equal amount.
HINT:
The backlash will change by about 0.02 mm (0.0008 in.) with
every 0.03 mm (0.0012 in.) change in the plate washer.
Washer thickness
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
2.57 − 2.59 (0.1012 − 0.1020)2.81 − 2.83 (0.1106 − 0.1114)3.05 − 3.07 (0.1201 − 0.1209)
2.60 − 2.62 (0.1024 − 0.1031)2.84 − 2.86 (0.1118 − 0.1126)3.08 − 3.10 (0.1213 − 0.1220)
2.63 − 2.65 (0.1035 − 0.1043)2.87 − 2.89 (0.1130 − 0.1138)3.11 − 3.13 (0.1224 − 0.1232)
2.66 − 2.68 (0.1047 − 0.1055)2.90 − 2.92 (0.1142 − 0.1150)3.14 − 3.16 (0.1236 − 0.1244)
2.69 − 2.71 (0.1059 − 0.1067)2.93 − 2.95 (0.1154 − 0.1161)3.17 − 3.19 (0.1248 − 0.1256)
2.72 − 2.74 (0.1071 − 0.1079)2.96 − 2.98 (0.1165 − 0.1173)3.20 − 3.22 (0.1260 − 0.1268)
2.75 − 2.77 (0.1083 − 0.1091)2.99 − 3.01 (0.1177 − 0.1185)3.23 − 3.25 (0.1272 − 0.1280)
2.78 − 2.80 (0.1094 − 0.1102)3.02 − 3.04 (0.1189 − 0.1197)−
12. INSTALL BEARING CAPS
Align the matchmarks on the 2 caps and carrier.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
13. MEASURE 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)
14. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat 3 or 4 teeth at three different positions on the ring
gear with red lead primer.
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.
Page 1534 of 2062
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SST
R11163SST
SA2351
SST
SA2352
SA−64
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
16. INSTALL OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09554−30011
Oil seal drive in depth: 1.5 mm (0.059 in.)
(b) Apply MP grease to the oil seal lip.
17. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange.
SST 09950−30010
(b) Coat the threads of a new nut with hypoid gear oil install
it.
(c) Using SST to hold the flange, tighten the nut.
SST 09330−00021
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
18. ADJUST DRIVE PINION PRELOAD
Using a torque wrench, measure the drive pinion preload using
the backlash of the drive pinion and the ring gear.
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)
If the preload is greater than the specification, replace the
spacer.
If the preload is less than the specification, retighten the nut a
little at a time with a torque of 13 N·m (130 kgf·cm, 9 ft·lbf) until
the specified preload is reached.
Page 1535 of 2062
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SST
SA0339
SST
SA0340
SA0370
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−65
1996 TOYOTA T100 (RM449U)
Maximum torque: 235 N·m (2,400 kgf·cm, 173 ft·lbf)
If the maximum torque is exceeded while retightening the nut,
replace the spacer and repeat the preload procedure. Do not
loosen the nut to reduce the preload.
19. RECHECK RING GEAR BACKLASH
(See page SA−57)
20. RECHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−57)
21. CHECK RUNOUT OF COMPANION FLANGE (See
page SA−48)
22. STAKE DRIVE PINION NUT
23. INSTALL RH SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, install a new oil seal until its
surface is flush with the differential carrier end.
SST 09550−00032, 09950−70010 (09951−07150)
(b) Apply MP grease to the oil seal lip.
24. INSTALL RH SIDE GEAR SHAFT
(a) Install a new snap ring to the side gear shaft.
(b) Using a plastic hammer, install the side gear shaft to the
differential case.
25. CHECK INSTALLATION OF SIDE GEAR SHAFT
(a) Check that there is 2 − 3 mm (0.08 − 0.12 in.) of play in
axial direction.
(b) Check that the side gear shaft will not come out by trying
to pull it completely out by hand.
26. INSTALL INTERMEDIATE SHAFT
(a) Install a new snap ring to the shaft.
(b) Using a plastic hammer, install the shaft to the differential
case.
27. CHECK INSTALLATION OF INTERMEDIATE SHAFT
(a) Check that there is 2 − 3 mm (0.08 − 0.12 in.) of play in
the axial direction.
(b) Check that the intermediate shaft will not come out by try-
ing to pull it completely out by hand.
Page 1536 of 2062
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SA0400
R11760
FIPG
SA0374
SA−66
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
28. INSTALL CLUTCH CASE TO SIDE GEAR SHAFT TUBE
(a) Install a new O−ring to the tube.
(b) Coat the O−ring with MP grease.
(c) Install the clutch case to the tube.
(d) Using a torx socket (E14), torque the 2 torx bolts.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
29. INSTALL CLUTCH SLEEVE
30. INSTALL LH SIDE GEAR SHAFT TO DIFFERENTIAL
CARRIER
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the differential carrier and
clutch case.
(b) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(c) Apply FIPG to the carrier, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the side gear shaft within 10 minutes after applying FIPG.
(d) Install LH side gear shaft to the differential carrier.
(e) Using a torx socket (E14), torque the 4 torx bolts.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
Page 1537 of 2062
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FIPG
Seal Width Approx.
1 − 2 mm (0.04 − 0.08 in.)
R11762
FIPG
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−67
1996 TOYOTA T100 (RM449U)
31. INSTALL DIFFERENTIAL CARRIER COVER
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the differential carrier and
carrier cover.
(b) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(c) Apply FIPG to the carrier cover, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the carrier cover within 10 minutes after applying FIPG.
(d) Install the differential carrier cover with the 8 bolts.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
32. INSTALL A.D.D. ACTUATOR
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the actuator and clutch case.
(b) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(c) Apply FIPG to the clutch case, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the actuator within 10 minutes after applying FIPG.
(d) Torque the 4 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
Page 1543 of 2062
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R03309
W00406
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER (2WD)
SA−73
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE SHOCK ABSORBER
(a) Remove the 2 bolts and disconnect the shock absorber
lower side from the lower suspension arm.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Hold the shock absorber and remove the set nut, 2 retain-
ers, cushion and shock absorber.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Remove the 2 retainers and cushion from the shock ab-
sorber.
Page 1548 of 2062
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R04246
SA−78
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER (4WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE SHOCK ABSORBER
(a) Remove the nut and washer, and disconnect the shock
absorber lower side from the lower suspension arm.
Torque: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
(b) Hold the shock absorber and remove the nut, retainer,
cushion and shock absorber.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Remove the 2 retainers and cushion from the shock ab-
sorber.
Page 1553 of 2062
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FA0037
A
R04273
R12264
LeftRight
R04275
− SUSPENSION AND AXLEFRONT TORSION BAR SPRING (2WD)
SA−83
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. MEASURE PROTRUDING BOLT END ”A” AS SHOWN
HINT:
Use this measurement for reference when adjusting the
vehicle height.
After stabilizing the suspension, adjust the vehicle height
by turning the adjusting nut (See page SA−7).
3. LOOSEN ADJUSTING NUT AND REMOVE ANCHOR
ARM
HINT:
At the time of installation, tighten the adjusting nut to the bolt
protrusion length is of before removal.
4. REMOVE TORSION BAR SPRING
HINT:
At the time of installation, please refer to the following items.
There are left and right matchmarks on the rear end of the
torsion bar springs.
Be careful not to interchange them.
Apply a light coat of MP grease to the spline of the torsion
bar spring.
5. REMOVE TORQUE ARM
Remove the 2 torque arm mounting nuts.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
