1996 TOYOTA T100 suspension

Downloaded from www.Manualslib.com manuals search engine SS−66
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
240 Author: Date:
1996 TOYOTA T100 (RM449U) Rear differential
Drive pinion bearing adjusting washer thickness
12 2.12 mm (0.0835 in.)
13 2.13 mm (0.0839 in.)
14 2.14 mm (0.0843 in.)
15 2.15 mm (0.0846 in.)
16 2.16 mm (0.0850 in.)
17 2.17 mm (0.0854 in.)
18 2.18 mm (0.0858 in.)
19 2.19 mm (0.0862 in.)
20 2.20 mm (0.0866 in.)
21 2.21 mm (0.0870 in.)
22 2.22 mm (0.0874 in.)
23 2.23 mm (0.0878 in.)
24 2.24 mm (0.0882 in.)
25 2.25 mm (0.0886 in.)
26 2.26 mm (0.0890 in.)
27 2.27 mm (0.0894 in.)
28 2.28 mm (0.0898 in.)

Downloaded from www.Manualslib.com manuals search engine SS083−02
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS−67
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Front (2WD)
Tie rod end lock nut5657041
Steering knuckle x Upper ball joint1081,10080
Steering knuckle x Lower ball joint1421,450105
Steering knuckle x Brake caliper1081,10080
Steering knuckle x Steering knuckle arm1831,870135
Dust cover x Steering knuckle1919514
Disc x Axle hub6465047
Upper suspension arm x Upper ball joint3132023
Lower suspension arm x Lower ball joint7576055
Torque arm x Lower suspension arm4950036
Shock absorber x Frame2525018
Lower suspension arm x Shock absorber1818513
Lower suspension arm x Stabilizer bar131309
Lower suspension arm shaft nut2062,100152
Upper suspension arm shaft x Frame9698071
Upper suspension arm shaft x Upper suspension arm1261,28093
Lower ball joint x Strut bar7576055
Strut bar x Frame1231,25090
Stabilizer bar link set nut131309
Stabilizer bar bracket x Frame3030622
Hub nut1031,05076
ABS speed sensor x Steering knuckle8.08271 in.·lbf
ABS Speed sensor wire harness x Upper suspension arm5.05144 in.·lbf
Front (4WD)
Knuckle stopper bolt lock nut4748035
Tie rod clamp bolt2222516
Steering knuckle x Upper ball joint1421,450105
Steering knuckle x Lower ball joint5859043
Steering knuckle x Brake caliper1231,25090
Flange x Axle hub3131523
Flange x Front drive shaft1818513
Axle hub bearing lock nut4748035
Oil seal x Dust cover1818513
Upper suspension arm x Upper ball joint3334025
Lower suspension arm x Lower ball joint1421,450105
Steering knuckle arm x Steering knuckle1831,870135
Upper suspension arm x Torque arm8789064
Upper suspension arm shaft lock nut2262,300166
Shock absorber x Frame2525018
Lower suspension arm x Shock absorber1371,400101
Lower suspension arm x Stabilizer bar2526019
Stabilizer bar bracket x Frame2930022

Downloaded from www.Manualslib.com manuals search engine SS−68
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
1996 TOYOTA T100 (RM449U)Part tightened
N·mkgf·cmft·lbf
Front drive shaft x Side gear shaft8384561
Lower suspension arm x Frame1962,000145
Upper suspension arm shaft x Frame1781,810131
Hub nut1031,05076
ABS speed sensor x Steering knuckle8.08271 in.·lbf
ABS speed sensor wire harness5.05144 in.·lbf
Companion flange x Front differential assembly1081,10080
Drain plug4950036
Filler plug3940029
Crossmember x Frame1261,28093
Front mounting bolt1471,500108
Rear mounting bolt1671,700123
Actuator x Clutch case cover2121015
Screw plug x Clutch case cover2020014
A.D.D. indicator switch x Clutch case cover4041030
Carrier cover x Oil deflector7.47565 in.·lbf
Ring gear x Differential case9798571
Differential carrier x Bearing cap7880058
Clutch case x Tube7880058
Clutch case x Differential carrier78800500
Differential x Front propeller shaft7475054
Clutch case cover x Clutch case2121015
Differential carrier cover x Differential carrier4747534
Tube x Bearing retainer121209
Rear
Ring gear x Differential case1251,27092
Bearing cap x Differential carrier11 31,15083
Differential carrier x Axle housing7374054
Rear axle housing x Rear brake assembly6970051
Rear shock absorber x Spring seat2626019
Rear shock absorber x Frame2626019
U−bolt x Spring seat1321,35097
Shackle pin x Leaf spring9193067
Differential x Propeller shaft7678056
Hanger pin x Leaf spring9193067
Hanger pin lock bolt2626019
Leaf spring center bolt4445033
Hub nut1031,05076
Spring bumper seat set bolt2930022
ABS speed sensor x Rear axle housing8.08271 in.·lbf
Brake line1515511
Parking brake set bolt2526019
Drain plug4950036
Filler plug3940029

Downloaded from www.Manualslib.com manuals search engine SS−74
− SERVICE SPECIFICATIONSSTEERING
1996 TOYOTA T100 (RM449U) Tie rod end lock nut
5657041
Turn pressure tube union nut10 (13)102 (130)7 (9)
PS gear assembly set bolt and nut8890065
Mount bracket x Suspension crossmember8890065
Control valve shaft x Intermediate shaft3536026
Pressure feed tube x Control valve housing19 (25)195 (250)14 (18)
Return tube x Control valve housing19 (25)195 (250)14 (18)
Tie rod end x Steering knuckle9092067
4WD:
Pressure feed tube x PS gear assembly36 (44)365 (450)26 (33)
Return tube x PS gear assembly36 (44)365 (450)26 (33)
PS gear assembly x Body1421450105
Pitman arm x Cross shaft1771800130
Cross shaft adjusting screw set nut4647034
Side cover x Gear housing6162045
Plunger guide nut2020515
Worm gear valve body assembly x Gear housing6162045
Worm gear valve body assembly x Intermediate shaft3536026
STEERING LINKAGE
Pitman arm x Cross shaft1771800130
Pitman arm x Relay rod9092067
Tie rod clamp bolt2222516
Tie rod assembly x Relay rod9092067
Tie rod assembly x Knuckle arm9092067
Idler arm assembly x Frame1421450105
Relay rod x Idler arm assembly5960043
Steering damper set bolt and nut2526019
Relay rod x Steering damper5960043
IDLER ARM
Idler arm x Idler arm bracket7880058
( ): For use without SST

Downloaded from www.Manualslib.com manuals search engine SA – SUSPENSION AND AXLE

TROUBLESHOOTING SA-1

TIRE AND WHEEL (2WD) SA-3
TIRE AND WHEEL (4WD) SA-5
FRONT WHEEL ALIGNMENT (2WD) SA-7
FRONT WHEEL ALIGNMENT (4WD) SA-10
FRONT AXLE HUB (2WD) SA-15
FRONT AXLE HUB (4WD) SA-22
FRONT WHEEL HUB BOLT (2WD) SA-27
STEERING KNUCKLE (4WD) SA-28
FRONT DRIVE SHAFT (4WD) SA-36
FRONT DIFFERENTIAL REAR OIL
SEAL (4WD) SA-42
FRONT DIFFERENTIAL CARRIER
(4WD) SA-45
A.D.D. CONTROL SYSTEM SA-69
FRONT SHOCK ABSORBER (2WD) SA-72
FRONT SHOCK ABSORBER (4WD) SA-77
FRONT TORSION BAR SPRING (2WD) SA-82
FRONT TORSION BAR SPRING (2WD) SA-85
FRONT STRUT BAR (2WD) SA-88
FRONT UPPER SUSPENSION ARM
(2WD) SA-91
FRONT UPPER SUSPENSION ARM
(4WD) SA-95
FRONT LOWER SUSPENSION ARM
(2WD) SA-99
FRONT LOWER SUSPENSION ARM
(4WD) SA-103

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FRONT UPPER BALL JOINT (2WD) SA-107
FRONT UPPER BALL JOINT (4WD) SA-111
FRONT LOWER BALL JOINT (2WD) SA-115
FRONT LOWER BALL JOINT (4WD) SA-119
FRONT STABILIZER BAR (2WD) SA-123
FRONT STABILIZER BAR (4WD) SA-126
REAR AXLE SHAFT SA-129
REAR WHEEL HUB BOLT SA-136
REAR DIFFERENTIAL CARRIER SA-137
REAR SHOCK ABSORBER SA-155
REAR LEAF SPRING SA-160

Downloaded from www.Manualslib.com manuals search engine SA0FC−01
− SUSPENSION AND AXLETROUBLESHOOTING
SA−1
1440 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Wander/pulls
1. Tires (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering linkage (Loosen or worn)
4. Hub bearings (Loosen or worn)
5. Suspension parts (Worn out)
6. Steering gear (Out of adjustment or broken)SA−3
SA−5
SA−7
SA−10
−
SA−15
SA−22
SA−129
−
−
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn out)−
SA−82
SA−85
SA−160
SA−72
SA−77
SA−155
Sways/pitches
1. Tires (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn out)SA−3
SA−5
SA−123
SA−126
SA−72
SA−77
SA−155
Front wheel shimmy
1. Tires (Worn or improperly inflated)
2. Wheels (Out of balance)
3. Shock absorber (Worn out)
4. Wheel alignment (Incorrect)
5. Ball joints (Worn)
6. Hub bearings (Loosen or worn)
7. Steering linkage (Loosen or worn)
8. Steering gear (Out of adjustment or broken)SA−3
SA−5
SA−3
SA−5
SA−72
SA−77
SA−155
SA−7
SA−10
SA−107
SA−11 1
SA−11 5
SA−11 9
SA−15
SA−22
SA−129
−
−
Abnormal tire wear
1. Tires (Improperly inflated)
2. Wheel alignment (Incorrect)
3. Suspension parts (Worn out)
4. Shock absorber (Worn out)SA−3
SA−5
SA−3
SA−5
−
SA−72
SA−77
SA−155

Downloaded from www.Manualslib.com manuals search engine SA−2
− SUSPENSION AND AXLETROUBLESHOOTING
1441 Author: Date:
1996 TOYOTA T100 (RM449U) Noise in front differential
1. Oil level (Low or wrong grade)
2. Excessive backlash between pinion and ring gear
3. Ring, pinion or side gears (Worn or chipped)
4. Pinion shaft bearing (Worn)
5. Side bearing (Worn)
6. Differential bearing (Loosen or worn)SA−42
SA−45
SA−45
SA−45
SA−45
SA−45
Oil leak from front differential
1. Oil level (Too high or wrong grade)
2. Front differential rear oil seal (Worn or damaged)
3. Side gear oil seal (Worn or damaged)
4. Companion flange (Loose or damaged)
5. Side gear shaft (Damaged)SA−42
SA−42
SA−45
SA−42
SA−45
Noise in rear axle
1. Oil level (Low or wrong grade)
2. Excessive backlash between pinion and ring gear
3. Ring, pinion or side gears (Worn or chipped)
4. Pinion shaft bearing (Worn)
5. Axle shaft bearing (Worn)
6. Differential bearing (Loosen or worn)SA−137
SA−137
SA−137
SA−137
SA−129
SA−137
Oil leak from rear axle1. Oil seal (Worn or damaged)
2. Rear axle housing (Cracked)SA−129
SA−129
Oil leak from rear differential
1. Oil level (Too high or wrong grade)
2. Oil seal (Worn or damaged)
3. Companion flange (Loose or damaged)SA−137
SA−137
SA−137