1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine Z03851
W00404
SST Front Rear
R01197
SST
R11163SST
SA2347
SST
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−59
1996 TOYOTA T100 (RM449U)
5. CHECK RING GEAR RUNOUT
(a) Install the differential case onto the carrier and install the
2 plate washers to fill the play in the bearing (See page
SA−57).
(b) Install 2 bearing caps (See page SA−57).
(c) Using a dial indicator, measure the runout of ring gear.
Maximum runout: 0.07 mm (0.0028 in.)
6. INSTALL DRIVE PINION FRONT AND REAR BEARING
OUTER RACES
(a) Using SST and a press, install the front side of the outer
race.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
(b) Using SST and a press, install the rear side of the outer
race.
SST 09950−60020 (09951−00790),
09950−70010 (09951−07150)
7. INSTALL DRIVE PINION FRONT BEARING
(a) Install the washer on the drive pinion.
HINT:
First fit a washer with the same thickness as the washer which
was removed, then after checking the tooth contact pattern, re-
place the washer with one of a different thickness if necessary.
(b) Using SST, install the front bearing onto the drive pinion.
SST 09506−30012
8. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion, rear bearing and oil slinger.
HINT:
Assemble the spacer and oil seal after adjusting the gear con-
tact pattern.
(b) Using SST, install the companion flange.
SST 09950−30010
(c) Coat the threads of the nut with hypoid gear oil.
(d) Adjust the drive pinion preload by tightening the compan-
ion flange nut.
Using SST to hold the flange, tighten the nut.
SST 09330−00021
NOTICE:
As there is no spacer, tighten the nut a little at a time, being
careful not to overtighten it.

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).

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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.

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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.

Downloaded from www.Manualslib.com manuals search engine SA0GB−01
SA0356
SA0361
SA0362
Port A
SA0363
Port B
SA0383
SA−70
− SUSPENSION AND AXLEA.D.D. CONTROL SYSTEM
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT CLUTCH HUB AND CLUTCH SLEEVE
(a) Check the clutch hub and clutch sleeve for wear and dam-
age.
(b) Check that clutch sleeve sides smoothly on the clutch
hub.
2. MEASURE CLEARANCE OF SLEEVE FORK AND
CLUTCH SLEEVE
Using a feeler gauge, measure the clearance between the
sleeve fork and the clutch sleeve.
Maximum clearance: 0.35 mm (0.0138 in.)
3. INSPECT A.D.D. ACTUATOR
(a) Check that the sleeve fork moves to the actuator side
when a vacuum of 66.7 kPa (500 mmHg, 19.69 in.Hg) is
applied to the port A. Also check that the vacuum remains
constant.
(b) Check that the sleeve fork moves away from the actuator
when a vacuum of 66.7 kPa (500 mmHg, 19.69 in.Hg) is
applied to port B. Also check that the vacuum remains
constant.
4. INSPECT A.D.D. SOLENOIDS
(a) Using an ohmmeter, measure the resistance of the sole-
noids.
Resistance: 37 − 44 Ω

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Air FilterE
F
SA0385
Air FilterE
F
SA0375
1
2 3
4
61
23
4
6
Z04174
Z04175
− SUSPENSION AND AXLEA.D.D. CONTROL SYSTEM
SA−71
1996 TOYOTA T100 (RM449U)
(b) Connect the battery to the solenoid.
Check that air flows from the port E to port F.
Check that air does not flow from the port E to the air filter.
(c) Disconnect the battery positive voltage from the solenoid.
Check that air flows from the port E to the air filter.
Check that air does not flow from the port E to port F.
5. INSPECT A.D.D. RELAY
(a) Using an ohmmeter, check that continuity exists between
terminals 1 and 3.
(b) Using an ohmmeter, check that continuity exists between
terminals 2 and 6.
(c) Connect the positive (+) lead from the battery to terminal
6 and the negative (−) lead to terminal 2.
(d) Using an ohmmeter, check that continuity exists between
terminals 1 and 4.
6. INSPECT A.D.D. INDICATOR SWITCH
(a) Using an ohmmeter, check that continuity exists between
terminals when the switch when the switch is pushed (dif-
ferential connected position).
(b) Using an ohmmeter, check that continuity doesn’t exists
when the switch is free (differential disconnected posi-
tion).
7. INSPECT TRANSFER INDICATOR SWITCH
(a) Using an ohmmeter, check that there is continuity be-
tween terminals between terminals when the switch is
pushed (transfer 4WD position).
(b) Using an ohmmeter, check that there is continuity be-
tween terminals when switch is free (transfer H2 position).

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SA0039
SA−74
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER (2WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber piston rod and check
that there is no abnormal resistance or unusual operation
sound.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When discarding the shock absorber, see DISPOSAL on
page SA−75.

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R04270
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER (4WD)
SA−79
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber piston rod and check
that there is no abnormal resistance or unusual operation
sound.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When discarding the shock absorber, see DISPOSAL on
page SA−80.