TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine MT056−01
Z03583
Q07394
SST
− MANUAL TRANSMISSION (R150, R150F)FRONT BEARING RETAINER OIL SEAL
MT−41
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE FRONT BEARING RETAINER
OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00510), 09950−70010
(09951−07150)
Drive in depth:
11.7 ± 0.5 mm (0.461 ± 0.020 in.) from retainer end

Downloaded from www.Manualslib.com manuals search engine MT058−04
Z16044
4WD:
Slotted Spring PinTransfer Adaptor
 Oil Seal
 O−Ring
Dust Deflector
 Oil Seal 2WD: Oil Receiver Reverse Restrict Pin
Oil Receiver PipeOil Receiver Reverse Restrict Pin
Extension Housing
 Non−reusable part
 Precoated partSlotted Spring PinSpeedometer Driven Gear
Plug

Plug

Plug MT−42
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
1297 Author: Date:
1996 TOYOTA T100 (RM449U)
EXTENSION HOUSING AND TRANSFER ADAPTOR
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine MT057−01
Q04410
Z03582
Q07365
SST
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
MT−43
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Remove the reverse restrict pin.
(1) Using a torx socket wrench (T40), remove the screw
plug.
(2) Using a pin punch and hammer, drive out the slotted
spring pin.
(3) Remove the reverse restrict pin.
(b) Inspect the reverse restrict pin.
Turn and push the reverse restrict pin by hand.
Check for smooth operation.
(c) Install the reverse restrict pin.
(1) Install the reverse restrict pin to the extension hous-
ing or transfer adaptor.
(2) Using a pin punch and hammer, drive in the slotted
spring pin, as shown.
(3) Apply sealant to the plug threads.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(4) Using a torx socket wrench (T40), install and torque
the screw plug.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
2. 2WD:
IF NECESSARY, REPLACE EXTENSION HOUSING
OIL SEAL
(a) Remove the dust deflector.
(b) Using a screwdriver, pry out the oil seal.
(c) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00570), 09950−70010
(09951−07150)
Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(d) Install the deflector.

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SST
MT−44
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
1996 TOYOTA T100 (RM449U)
3. 4WD:
IF NECESSARY, REPLACE TRANSFER ADAPTOR OIL
SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00570), 09950−70010
(09951−07150)
Drive in depth: 45.6 ± 0.5 mm (1.795 ± 0.020 in.)

Downloaded from www.Manualslib.com manuals search engine MT – MANUAL TRANSMISSION (W59)

MANUAL TRANSMISSION SYSTEM MT-1
TROUBLESHOOTING MT-2
MANUAL TRANSMISSION UNIT MT-3
MANUAL TRANSMISSION ASSEMBLY MT-6
INPUT SHAFT MT-18
OUTPUT SHAFT MT-21
COUNTER GEAR AND REVERSE
IDLER GEAR MT-30
FRONT BEARING RETAINER OIL SEAL MT-38
EXTENSION HOUSING MT-40

Downloaded from www.Manualslib.com manuals search engine MT03H−01
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION SYSTEM
MT−1
1300 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION SYSTEM
PRECAUTION
When working with FIPG material, you must observe the following items.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.

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MT−2
− MANUAL TRANSMISSION (W59)TROUBLESHOOTING
1301 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
Noise
1. Oil (Level low)
2. Oil (Wrong)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−4
MT−4
MT−6
MT−6
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MT−4
MT−6
MT−6
MT−6
Hard to shift or will not shift
1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)MT−18
MT−21
MT−30
MT−18
MT−21
MT−30
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−6
MT−6
MT−6
MT−6

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D10953
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION UNIT
MT−3
1302 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION UNIT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine MT0ES−01
D10954
D10955
MT−4
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION UNIT
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION WITH ENGINE (See page
EM−65)
2. REMOVE REAR END PLATE
Remove the 4 bolts, 2 nuts and rear end plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
3. REMOVE STARTER
Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
4. REMOVE TRANSMISSION FROM ENGINE
(a) Remove the 3 transmission mounting bolts from the en-
gine.
Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
(b) Pull out the transmission toward the rear.
HINT:
At the time of installation, please refer to the following item.
Align the input shaft spline with the clutch disc and install the
transmission to the engine.
5. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

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− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION UNIT
MT−5
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page MT−4).
HINT:
After installation, do the road test.