1996 TOYOTA T100 power steering

Downloaded from www.Manualslib.com manuals search engine R01241
R01286
SST
Matchmarks
R01287
SST
R01290
− STEERINGPOWER STEERING GEAR (4WD)
SR−81
1996 TOYOTA T100 (RM449U)
4. INSTALL SECTOR SHAFT AND SIDE COVER
(a) Coat a new O−ring with power steering fluid and install it
the side cover.
(b) Assemble the sector shaft to the side cover.
HINT:
Fully loosen the sector shaft adjusting screw.
(c) Set the power piston nut at the center of the gear housing.
(d) Install and push the sector shaft into the gear housing so
that the center teeth mesh together.
(e) Torque the 4 bolts in a diagonal pattern.
Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
5. DETERMINE CENTER POSITION
(a) Using SST, turn the worm gear valve body shaft so full
lock in both directions and determine the exact center.
SST 09616−00010
(b) Place matchmarks on the worm gear valve body shaft and
gear housing to show neutral position.
6. ADJUST SECTOR SHAFT ADJUSTING SCREW
(a) Install SST with a torque wrench on the worm gear valve
body shaft.
SST 09616−00010
(b) Turn the adjusting screw until the preload is within the
specification.
Preload (Turning):
0.2 − 0.4 N·m (2 − 4 kgf·cm, 1.7 − 3.5 in.·lbf)
7. INSTALL NEW SEAL WASHER
8. INSTALL ADJUSTING SCREW LOCK NUT
Torque the lock nut while holding the sector shaft adjusting
screw.
Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine R01288
SST SR−82
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
9. CHECK TOTAL PRELOAD
Using SST and a torque wrench, check total preload.
SST 09616−00010
Total preload (Turning):
0.5 − 0.9 N·m (5 − 9.5 kgf·cm, 4.3 − 8.3 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine SR085−01
R15509
Fulcrum
Length
SST
SR2922
Alignment Marks
− STEERINGPOWER STEERING GEAR (4WD)
SR−83
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Install the 3 bolts, washers and nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
2. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
3. CONNECT PRESSURE FEED TUBE AND RETURN
TUBE
Using SST, connect the tube.
SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT PITMAN ARM SUB−ASSEMBLY WITH
RELAY ROD
(a) Align the alignment marks on the pitman arm and sector
shaft, and connect the pitman arm.
(b) Install the spring washer and pitman arm set nut.
Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
5. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
6. CENTER SPIRAL CABLE
(See page SR−20)
7. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering column
main shaft.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
8. BLEED POWER STEERING SYSTEM
(See page SR−4)
9. CHECK STEERING WHEEL CENTER POINT
10. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
11. INSTALL STEERING WHEEL PAD
(See page SR−20)
12. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)

Downloaded from www.Manualslib.com manuals search engine RS03H−01
− SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS−1
1768 Author: Date:
1996 TOYOTA T100 (RM449U)
SRS AIRBAG
PRECAUTION
NOTICE:
The TOYOTA T100 is equipped with SRS, which comprises a driver airbag. Failure to carry out
service operations in the correct sequence could cause the SRS to unexpectedly deploy during
servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the
SRS, it is possible that the SRS may fail to operate when required. Before performing servicing
(including removal or installation of parts, inspection or replacement), be sure to read the fol-
lowing items carefully, then follow the correct procedures described in the repair manual.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting. When troubleshooting the SRS, always in-
spect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, air-
bag sensor assembly and front airbag sensor should be inspected (See page RS−9, RS−23 and
RS−28).
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, airbag sensor assembly or front airbag
sensor in order to reuse it.
If the steering wheel pad, airbag sensor assembly or front airbag sensor has been dropped, or
if there are cracks, dents or other defects in the case, bracket or connector, replace them with
new ones.
Use a volt/ohmmeter with high impedance ( 10 kΩ/V minimum) for troubleshooting the system’s
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions on the notices.
After work on the SRS is completed, perform the SRS warning light check or SRS side airbag
warning light check (See page DI−365).
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
CAUTION:
Work must be started after 90 seconds from when the ignition switch is turned to the ”LOCK”
position and the negative (−) terminal cable is disconnected from the battery.
(The SRS is equipped with a back−up power source so that if work is started within 90 seconds
from disconnecting the negative (−) terminal cable of the battery, the SRS may be deployed.)
When the negative (−) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as they
were before and adjust the clock. To avoid erasing the memory in each memory system, never
use a back− up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Do not expose the steering wheel pad, airbag sensor assembly or front airbag sensor directly
to hot air or flames.

Downloaded from www.Manualslib.com manuals search engine Z14845
Safing SensorFig.1
Power Source
Fig.2
Squib
Front
Airbag
Sensor Center
Airbag
Sensor RS−6
− SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
1996 TOYOTA T100 (RM449U)
(b) When the vehicle is involved in a frontal collision in the
hatched area (Fig. 1) and the shock is larger than the pre-
determined level, the SRS is activated automatically. A
safing sensor is designed to go on at a smaller decelera-
tion rate than the airbag sensor. As illustrated in Fig. 2,
ignition is caused when current flows to the squib, which
happens when a safing sensor and the airbag sensor go
on simultaneously. When deceleration force acts on the
sensors, squib in the driver airbag ignite and generate
gas. The gas discharging into the driver airbag rapidly in-
creases the pressure inside the bags, breaking open the
steering wheel pad.
Bag inflation then ends, and the bags deflate as the gas
is discharged through discharge holes at the bag’s rear or
side.

Downloaded from www.Manualslib.com manuals search engine AB0158
Battery
SST
AB0152
SST
AB0158
Battery
SST
H01580
SST
RS−12
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 TOYOTA T100 (RM449U)
1. AIRBAG DEPLOYMENT WHEN SCRAPPING VE-
HICLE
HINT:
Have a battery ready as the power source to deploy the airbag.
(a) Check functioning of SST
CAUTION:
When deploying the airbag, always use the specified SST:
SRS Airbag Deployment Tool.
SST 09082−00700
(1) Connect the SST battery.
Connect the red clip of the SST to the battery posi-
tive (+) terminal and the black clip to the battery neg-
ative (−) terminal.
HINT:
Do not connect the yellow connector which will be connected
with the supplemental restraint system.
(2) Check functioning of SST.
Press the SST activation switch, and check that the
LED of the SST activation switch lights up.
CAUTION:
If the LED lights up when the activation switch is not being
pressed, SST malfunction is probable, so definitely do not
use the SST.
(b) Install the SST.
CAUTION:
Check that there is no looseness in the steering wheel and
steering wheel pad.
(1) Disconnect the airbag connector of the spiral cable.

Downloaded from www.Manualslib.com manuals search engine R05747
Inflater
Cover
Connector
R05748
L
M
AB0163
Stripped Wire Harness SectionWire Harness
Diameter RS−14
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 TOYOTA T100 (RM449U)
2. DEPLOYMENT WHEN DISPOSING OF STEERING
WHEEL PAD ONLY
NOTICE:
When disposing of the steering wheel pad (with air-
bag) only, never use the customers vehicle to deploy
the airbag.
Be sure to follow the procedure given below when de-
ploying the airbag.
HINT:
Have a battery ready as the power source to deploy the airbag.
(a) Remove the steering wheel pad.
(See page SR−13 or SR−26)
CAUTION:
When storing the steering wheel pad, keep the upper sur-
face of the pad facing upward.
(b) Remove the steering wheel pad connector.
Remove the connector on the rear surface of the steering
wheel pad from the bracket.
(c) Fix steering wheel pad to disc wheel with tire.
(1) Install the 2 bolt with washers in the 2 bolt holes in
the steering wheel pad.
Bolt:
L: 35. mm (1.387 in.)
M: 6.0 mm (0.236 in.)
Pitch: 1.0 mm (0.039 in.)
NOTICE:
Tighten the bolts by hand until the bolts become diffi-
cult to turn.
Do not tighten the bolts too much.
(2) Using a service−purpose wire harness tie down the
steering wheel pad to the disc wheel.
Wire harness: Stripped wire harness section
1.25 mm
2
or more (0.0019 in2. or more).
HINT:
To calculate the square of the stripped wire harness section:
Square = 3.14 x (Diameter)
2
divided by 4