TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine MT03M−03
Z15702
Clutch Housing Cover
Snap Ring
Transmission Case
Front Bearing
Clutch HousingFiller Plug Drain Plug Retainer
Release
Fork Support
Straight Screw Plug
Intermediate PlateOutput Shaft
Locking Ball

x 7 x 9
BootBack−Up
Light Switch
Restrict PinControl Shift Lever
Retainer
Oil Baffle Plate
Restrict Pin
Extension Housing Speedometer Driven Gear
Non−reusable part
Precoated partInput Shaft
x 6
x 9Straight Screw Plug
Spring 
 

Gasket
Gasket Gasket
Gasket
Gasket

39 (400, 29)
MT−6
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1305 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION ASSEMBLY
COMPONENTS

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− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−7
1306 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine MT03N−04
Q06713
Q06714
FIPG
Q06715
FIPG
x 7 MT−8
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE BACK−UP LIGHT SWITCH
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
2. REMOVE SPEEDOMETER DRIVEN GEAR
Remove the lock plate set bolt and driven gear.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
3. REMOVE CLUTCH HOUSING FROM TRANSMISSION
CASE
Remove the 9 bolts and clutch housing.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE CONTROL SHIFT LEVER RETAINER
(a) Remove the 6 bolts.
Sealant:
Part No.08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the control shift lever retainer and oil baffle plate.
5. REMOVE 2 RESTRICT PINS AND GASKETS
HINT:
At the time of reassembly, please refer to the following item.
Install the black pin on the reverse gear/5th gear side.
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
6. REMOVE EXTENSION HOUSING
(a) Remove the shift lever housing set bolt.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Remove the 9 bolts from the extension housing.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(c) Using a plastic hammer, carefully tap the extension hous-
ing.
(d) Disengage the shift and select lever from the shift head.
(e) Pull out the extension housing.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or equiva-
lent
7. REMOVE FRONT BEARING RETAINER AND BEAR-
ING SNAP RING
(a) Remove the 7 bolts.
Sealant:
Part No.08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Remove the front bearing retainer.

Downloaded from www.Manualslib.com manuals search engine Q06716FIPG
Q03881
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−9
1996 TOYOTA T100 (RM449U)
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or equiva-
lent
(c) Using a snap ring expander, remove the 2 bearing snap
rings.
8. SEPARATE INTERMEDIATE PLATE FROM TRANS-
MISSION CASE
(a) Using a plastic hammer, carefully tap the transmission
case.
(b) Pull the transmission case from the intermediate plate.
NOTICE:
At the time of reassembly, please refer to the following
item.
Align each bearing outer race and each shift fork shaft end
with the case holes.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or equiva-
lent
9. MOUNT INTERMEDIATE PLATE IN VISE
(a) Use the 2 long clutch housing bolts, plate washers and
suitable nuts, as shown.
HINT:
Increase or decrease plate washers so that the bolt tip does not
protrude from the nut.
(b) Mount the intermediate plate in a vise.
10. REMOVE OIL SEPARATOR
Remove the 2 bolts and oil separator.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
11. REMOVE FRONT MAGNET

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Short
Middle
Long
Q06717
D00861
D00862
D10957
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− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
12. REMOVE LOCKING BALL AND SPRING
(a) Using a hexagon wrench, remove the 4 straight screw
plugs.
Sealant:
Part No.08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the 3 springs and balls.
13. REMOVE SHIFT FORK, SHIFT FORK SHAFT AND RE-
VERSE IDLER GEAR
(a) Remove the No.1 and No.2 shift fork set bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Remove the bolt and reverse idler gear shaft stopper.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Remove the reverse idler gear and shaft with the snap
ring.
(d) Remove the No.1 shift fork and shaft.
(e) Using a magnetic finger, remove the No.1 and No.2 inter-
lock pins.
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the No.1 and No.2 interlock pins.
(f) Using 2 screwdrivers and a hammer, tap out the No. 2 shift
fork shaft snap ring.
(g) Remove the No. 2 shift fork and shaft.
(h) Using a magnetic finger, remove the No. 3 interlock pin.
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the No.3 interlock pin.
(i) Using a pin punch and hammer, drive out the No. 3 shift
fork pin.
(j) Using a hexagon wrench, remove the plug.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(k) Using a magnetic finger, remove the spring and ball.

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Q06720
Removal Installation
WM0041
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−11
1996 TOYOTA T100 (RM449U)
(l) Pull out the No.4 shift fork shaft.
(m) Remove the pin from the reverse shift head.
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the pin.
(n) Remove the No.3 shift fork, fork shaft and reverse shift
arm with the snap ring.
HINT:
At the time of reassembly, please refer to the following item.
Align the No.3 shift fork with the No.3 hub sleeve groove, put
the reverse shift arm into the pivot of bearing retainer and align
the reverse shift arm shoe with the reverse idler gear groove.
14. REMOVE SPEEDOMETER DRIVE GEAR
Pry out both ends of the clip and remove the drive gear.
15. INSPECT COUNTER 5TH GEAR THRUST CLEAR-
ANCE
Using a feeler gauge, measure the counter 5th gear thrust
clearance.
Standard clearance:
0.10 − 0.41 mm (0.0039 − 0.0161 in.)
Maximum clearance:
0.46 mm (0.0181 in.)

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Q06283
SST
D00864
Socket Wrench
Q00987
MT−12
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
16. REMOVE COUNTER REAR BEARING, SPACER,
COUNTER 5TH GEAR AND NEEDLE ROLLER BEAR-
ING
(a) Using a snap ring expander, remove the snap ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
11.90 − 1.95 (0.0748 − 0.0768)
21.96 − 2.01 (0.0772 − 0.0791)
32.02 − 2.07 (0.0795 − 0.0815)
42.08 − 2.13 (0.0819 − 0.0839)
52.14 − 2.19 (0.0843 − 0.0862)
62.20 − 2.25 (0.0866 − 0.0886)
72.26 − 2.31 (0.0890 − 0.0909)
(b) Using SST, remove the rear bearing, spacer, counter 5th
gear and bearing.
SST 09950−40010
NOTICE:
Be careful not to catch the output shaft rear bearing roller
on the counter 5th gear.
(c) Remove the spacer.
HINT:
At the time of reassembly, please refer to the following items.
Install the counter 5th gear with the 5th gear gaps aligned
with the synchronizer cone ring pin.
Using a socket wrench and hammer, drive in the bearing.
When driving in the bearing, support the counter shaft in
front with a 1.4 − 2.3 kg (3 − 5 lb) hammer or equivalent.
17. REMOVE SYNCHRONIZER RING ASSEMBLY WITH
NO.3 HUB SLEEVE AND NO.3 CLUTCH HUB
(a) Remove the synchronizer ring assembly with the No.3
hub sleeve from the No.3 clutch hub.

Downloaded from www.Manualslib.com manuals search engine Q04007
Q06285
SST
D00865
SST Front
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−13
1996 TOYOTA T100 (RM449U)
(b) Remove the spacer.
(c) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
22.06 − 2.11 (0.0811 − 0.0831)
32.12 − 2.17 (0.0835 − 0.0854)
42.18 − 2.23 (0.0858 − 0.0878)
52.24 − 2.29 (0.0882 − 0.0902)
(d) Using SST, remove the No.3 clutch hub.
SST 09950−40010
HINT:
At the time of reassembly, please refer to the following items.
Using SST and a hammer, drive in the No.3 clutch hub.
SST 09316−60011 (09316−00011, 09316−00071)
When installing the No.3 clutch hub, support the counter
shaft in front with a 1.4 − 2.3 kg (3 − 5 lb) hammer or equiv-
alent.
18. REMOVE REAR MAGNET

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WM0046
SST
D00867
SSTSST
MT−14
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
19. REMOVE OUTPUT SHAFT REAR BEARING AND 5TH
GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
82.31 − 2.36 (0.0909 − 0.0929)
92.37 − 2.42 (0.0933 − 0.0953)
102.43 − 2.48 (0.0957 − 0.0976)
112.49 − 2.54 (0.0980 − 0.1000)
122.55 − 2.60 (0.1004 − 0.1024)
132.61 − 2.66 (0.1028 − 0.1047)
142.68 − 2.73 (0.1055 − 0.1075)
152.74 − 2.79 (0.1079 − 0.1098)
(b) Using SST, remove the rear bearing and 5th gear.
SST 09312−20011 (09313−00030, 09313−00040,
09313−00050)
HINT:
At the time of reassembly. please refer to the following item.
Using SST, install the 5th gear and rear bearing.
SST 09312−20011 (09313−00010, 09313−00030,
09313−00040, 09313−00050)

Downloaded from www.Manualslib.com manuals search engine D00868
Q05168
SST
D00870
SST
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−15
1996 TOYOTA T100 (RM449U)
20. REMOVE REVERSE GEAR
(a) Using a snap ring expander, remove the snap ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
52.25 − 2.30 (0.0886 − 0.0906)
112.30 − 2.35 (0.0906 − 0.0925)
122.35 − 2.40 (0.0925 − 0.0945)
132.40 − 2.45 (0.0945 − 0.0965)
142.45 − 2.50 (0.0965 − 0.0984)
152.50 − 2.55 (0.0984 − 0.1004)
162.55 − 2.60 (0.1004 − 0.1024)
172.61 − 2.66 (0.1028 − 0.1047)
182.67 − 2.72 (0.1051 − 0.1071)
192.73 − 2.78 (0.1075 − 0.1094)
202.79 − 2.84 (0.1098 − 0.1118)
212.85 − 2.90 (0.1122 − 0.1142)
222.91 − 2.96 (0.1146 − 0.1165)
232.97 − 3.02 (0.1169 − 0.1189)
(b) Using SST, remove the reverse gear.
SST 09950−40010
HINT:
At the time of reassembly, please refer to the following item.
Using SST, install the reverse gear.
SST 09312−20011 (09313−00030, 09313−00040,
09313−00050)
21. REMOVE REAR BEARING RETAINER
(a) Using a torx socket wrench (T40), unscrew the 4 torx
screws and remove the rear bearing retainer.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)