TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine MT04S−05
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−21
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MT−13).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

Downloaded from www.Manualslib.com manuals search engine MT04T−01
WM0301
Snap Ring
 Bearing
Input ShaftBearing
Synchronizer Ring
 Non−reusable part MT−22
− MANUAL TRANSMISSION (R150, R150F)INPUT SHAFT
1277 Author: Date:
1996 TOYOTA T100 (RM449U)
INPUT SHAFT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Q00550
MT04U−01
Z03541
− MANUAL TRANSMISSION (R150, R150F)INPUT SHAFT
MT−23
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.

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Z03543
Z03544
SST
Z03545
MT−24
− MANUAL TRANSMISSION (R150, R150F)INPUT SHAFT
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the bearing.
(c) Using SST and a press, install a new bearing.
SST 09506−35010
(d) Select a snap ring that allows minimum axial play.
MarkThickness mm (in.)
A2.10 − 2.15 (0.0827 − 0.0846)
B2.15 − 2.20 (0.0846 − 0.0866)
C2.20 − 2.25 (0.0866 − 0.0886)
D2.25 − 2.30 (0.0886 − 0.0906)
E2.30 − 2.35 (0.0906 − 0.0925)
F2.35 − 2.40 (0.0925 − 0.0945)
G2.40 − 2.45 (0.0945 − 0.0965)
(e) Using a snap ring expander, install the snap ring.

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D10951
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−25
1280 Author: Date:
1996 TOYOTA T100 (RM449U)
OUTPUT SHAFT
COMPONENTS

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Q06818
3rd 1st
Z03552
2nd
Z03553
RM0012
MT−26
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE
Measure the thrust clearance of each gear.
Standard clearance:
1st gear: 0.15 − 0.45 mm (0.0059 − 0.0177 in.)
2nd and 3rd gears: 0.10 − 0.25 mm (0.0039 − 0.0098 in.)
Maximum clearance:
1st gear: 0.50 mm (0.0197 in.)
2nd and 3rd gears: 0.30 mm (0.0118 in.)
2. INSPECT EACH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of each
gear.
Standard clearance:
1st gear:
0.020 − 0.073 mm (0.0008 − 0.0029 in.)
2nd and 3rd gears:
0.015 − 0.068 mm (0.0006 − 0.0027 in.)
Maximum clearance:
1st gear: 0.160 mm (0.0063 in.)
2nd and 3rd gears: 0.160 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE 5TH GEAR, OUTPUT SHAFT CENTER
BEARING AND 1ST GEAR ASSEMBLY
(a) Using a press, remove the 5th gear, center bearing, thrust
washer and 1st gear.
(b) Remove the synchronizer ring.
(c) Remove the straight pin and needle roller bearing.
(d) Remove the spacer.

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Q00888
Z03550
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−27
1996 TOYOTA T100 (RM449U)
4. REMOVE REVERSE GEAR ASSEMBLY AND 2ND
GEAR ASSEMBLY
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
(b) Using a press, remove the reverse gear assembly and
2nd gear assembly.
(c) Remove the needle roller bearing.
5. REMOVE REVERSE GEAR, SHIFTING KEY AND
SPRING FROM CLUTCH HUB NO.1
(a) Remove the reverse gear from the clutch hub No.1.
(b) Push the shifting key spring with a screwdriver, remove
the 3 shifting keys and key springs.
6. REMOVE HUB SLEEVE NO.2 ASSEMBLY AND 3RD
GEAR ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the hub sleeve No.2 assembly and
3rd gear assembly.
(c) Remove the needle roller bearing.
7. REMOVE SHIFTING KEY AND SPRING FROM HUB
SLEEVE NO.2 ASSEMBLY
Using a screwdriver, remove the 3 shifting keys and 2 springs.

Downloaded from www.Manualslib.com manuals search engine Z03554
MT04Y−05
Z03555
AB
C
Z03556
WM0064
MT−28
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT OUTPUT SHAFT
(a) Using a micrometer, measure the output shaft flange
thickness.
Minimum thickness: 4.70 mm (0.1850 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
A 1st gear: 38.860 mm (1.5299 in.)
B 2nd gear: 46.860 mm (1.8449 in.)
C 3rd gear: 37.860 mm (1.4905 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)
If the runout exceeds the maximum, replace the output shaft.
2. INSPECT 1ST AND 3RD GEARS SYNCHRONIZER
RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.

Downloaded from www.Manualslib.com manuals search engine WM0065
Q00930
MT0780
D10952
WM0066
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−29
1996 TOYOTA T100 (RM449U)
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
3. INSPECT 2ND GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer inner ring, middle ring and outer
ring to each gear.
(c) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
4. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

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Q06699
Front
Q00888
Q06700
Front
Z03558
MT−30
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL CLUTCH HUB NO.2 INTO HUB SLEEVE NO.2
(a) Install the clutch hub No.2 and shifting keys to the hub
sleeve No.2.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not
aligned.
2. INSTALL CLUTCH HUB NO.1 INTO REVERSE GEAR
(a) Install the 3 shifting key springs to the clutch hub No.1.
(b) While pushing the shifting key spring with a screwdriver,
install the 3 shifting keys.
(c) While pushing the 3 shifting keys, install the clutch hub
No.1 to the reverse gear, as shown.
3. INSTALL 3RD GEAR AND HUB SLEEVE NO.2 ON
OUTPUT SHAFT
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Install the needle roller bearing in the 3rd gear.