1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine SA0FU−01
FA0735
SA−32
− SUSPENSION AND AXLESTEERING KNUCKLE (4WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT STEERING KNUCKLE
Using a dye penetrant, check the steering knuckle for cracks.

Downloaded from www.Manualslib.com manuals search engine SA0FW−02
R04389
FA0781
Z03703
SA−34
− SUSPENSION AND AXLESTEERING KNUCKLE (4WD)
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL STEERING KNUCKLE
(a) Apply synthetic oil and lithium soap base chassis grease,
NLGI No.1 to the drive shaft.
(b) Push down the lower suspension arm and install the
steering knuckle.
NOTICE:
Be careful not to damage the oil seal and boot.
(c) Connect the lower ball joint to the steering knuckle, install
and torque the nut.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
(d) Install a new cotter pin.
(e) Connect the upper ball joint to the steering knuckle, install
and torque the 4 nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
(f) Install a new cotter pin.
(g) Install the spacer to the drive shaft.
(h) Using snap ring pliers, install the snap ring.
NOTICE:
If you replace the steering knuckle bushing, recheck the
drive shaft thrust clearance.
(i) Install the bolt in the drive shaft.
(j) Using a feeler gauge, measure the drive shaft thrust
clearance between the steering knuckle outside bushing
and spacer, by pulling the bolt and applying a load of 98
N (10 kgf, 22.0 lbf).
Front drive shaft thrust clearance:
Standard: 0.10 − 0.50 mm (0.0039 − 0.0197 in.)
If the clearance is not within specification, replace the spacer.
Spacer thickness
1.80 mm (0.0709 in.)2.25 mm (0.0886 in.)
2. CONNECT STABILIZER BAR TO LOWER
SUSPENSION ARM
(a) Connect the stabilizer bar to the lower suspension arm
with the bolt, 5 retainers, 4 cushions, collar and a new nut,
as shown in the illustration.
(b) Torque the nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine − SUSPENSION AND AXLESTEERING KNUCKLE (4WD)
SA−35
1996 TOYOTA T100 (RM449U)
3. CONNECT FRONT SHOCK ABSORBER TO LOWER
SUSPENSION ARM
Install the shock absorber, bolt, washer and nut to the lower
suspension arm.
Torque: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
4. INSTALL DUST COVER AND NEW OIL SEAL
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
5. INSTALL FRONT AXLE HUB AND BRAKE CALIPER
(See page SA−25)
6. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)
7. w/ ABS:
CHECK ABS SPEED SENSOR SIGNAL
(See page DI−321)

Downloaded from www.Manualslib.com manuals search engine SA0FZ−02
FA0810
FA0838
Matchmarks
SA1443Matchmarks
FA0841
SA−38
− SUSPENSION AND AXLEFRONT DRIVE SHAFT (4WD)
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see there is no play in the inboard and outboard
joints.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no obvious play in the radial
direction of the universal joints.
(d) Check the boot for damage.
2. REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
(a) Using a screwdriver, remove the 4 boot clamps.
(b) Slide the inboard joint boot toward the outboard joint.
3. DISASSEMBLE INBOARD JOINT TULIP
(a) Place matchmarks on the inboard joint tulip and drive
shaft.
(b) Remove the inboard joint tulip from the drive shaft.
4. DISASSEMBLE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
(b) Place matchmarks on the shaft and tripod.
(c) Using a brass bar and hammer, remove the tripod from
the drive shaft.
NOTICE:
Do not tap the roller.
5. REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS AND BOOTS
NOTICE:
Do not disassemble the outboard joint.
6. REMOVE DUST DEFLECTOR
Using a screwdriver and hammer, remove the dust deflector.

Downloaded from www.Manualslib.com manuals search engine FA0811
SA−40
− SUSPENSION AND AXLEFRONT DRIVE SHAFT (4WD)
1996 TOYOTA T100 (RM449U)
6. ASSEMBLE NEW BOOT CLAMPS TO BOTH BOOTS
(a) Make sure the 2 boots are on the shaft groove.
(b) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Standard length:
481.2 − 491.2 mm (18.945 − 19.339 in.)
(c) Using a screwdriver, bend the clamp and lock with a
screwdriver.
7. CHECK DRIVE SHAFT (See page SA−38)

Downloaded from www.Manualslib.com manuals search engine SA0G1−01
− SUSPENSION AND AXLEFRONT DRIVE SHAFT (4WD)
SA−41
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−37).
AFTER INSTALLATION, CHECK FRONT WHEEL ALIGNMENT (See page SA−10)

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 Z03854
Z03853
Z03852
SA2349
SST
R11391SST SA−50
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
1996 TOYOTA T100 (RM449U)
12. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace the ring gear
and drive pinion as a set.
13. CHECK RING GEAR BACKLASH
(a) Fix the dial indicator on the tooth surface at a 90° angle.
(b) Using a dial indicator, with holding the drive pinion flange
and measure the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0070 in.)
If the backlash is not within the specification, adjust the ring
gear backlash.
HINT:
Measure from 3 or more places on the circumference of the ring
gear.
14. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−57)
15. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake the nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
(c) Using SST, remove the companion flange.
SST 09950−30010