TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine TR0CY−02
TF0626
Breather Hose
Transmission Side Transfer Side
TF0633
TF0655
TF0654
− TRANSFERTRANSFER UNIT
TR−3
1383 Author: Date:
1996 TOYOTA T100 (RM449U)
TRANSFER UNIT
REMOVAL
1. REMOVE TRANSFER WITH TRANSMISSION
M/T (See page MT−7)
A/T (See page AT−34)
HINT:
At the time of installation, shift the 2 shift fork shafts to the H4
position.
2. A/T:
REMOVE BREATHER HOSE
Disconnect the breather hose from transfer upper cover and
transmission control retainer.
Hose depth: 13 mm (0.51 in.) or more
3. REMOVE DYNAMIC DAMPER
Remove the 2 bolts and dynamic damper.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the trans-
mission.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
5. REMOVE PROPELLER SHAFT UPPER DUST COVER
AND TRANSFER FROM TRANSMISSION
(a) Remove the dust cover bolt from the bracket.
Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)
(b) Remove the transfer adapter rear mounting bolts.
(c) Pull the transfer straight up and remove it from the trans-
mission.
HINT:
Take care not to damage the adaptor rear oil seal with the trans-
fer input gear spline.

Downloaded from www.Manualslib.com manuals search engine TR01T−01
TR−4
− TRANSFERTRANSFER UNIT
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page TR−3).
1. APPLY MP GREASE TO TRANSFER ADAPTOR OIL SEAL
2. AFTER INSTALLATION, DO ROAD TEST

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− TRANSFERTRANSFER ASSEMBLY
TR−5
1385 Author: Date:
1996 TOYOTA T100 (RM449U)
TRANSFER ASSEMBLY
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR−6
− TRANSFERTRANSFER ASSEMBLY
1386 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine TR0CZ−01
TF0629
TF0447
Q09400
FIPG
− TRANSFERTRANSFER ASSEMBLY
TR−7
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE SPEEDOMETER DRIVEN GEAR
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
2. REMOVE TRANSFER INDICATOR SWITCH
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
3. A/T:
REMOVE TRANSFER L4 AND NEUTRAL POSITION
SWITCH
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
HINT:
At the time of installation, check the following items.
Check to see that the input shaft and output shafts rotate
smoothly.
Check to see that shifting can be made smoothly to all
position.
4. A/T:
REMOVE SHIFT GEAR HEAD NO.1 AND NO.2
(a) Using a pin punch and hammer, drive out the 2 slotted
spring pins.
(b) Remove the 2 shift gear heads.
5. REMOVE FRONT RETAINER
(a) Remove the 7 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the bolts.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a plastic hammer, tap the front retainer and remove
it.
HINT:
At the time of installation, please refer to the following items.
Remove any FIPG material and be careful not to drop oil
on the contacting surfaces of the front retainer.
Apply FIPG to the front retainer, as shown.
FIPG:
Part No.08826−00090, THREE BOND 1281,
LOCTITE 242 or equivalent

Downloaded from www.Manualslib.com manuals search engine TF0448
TF0614
TF0451
SST
Q06503
SST TR−8
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
6. M/T:
REMOVE CONTROL RETAINER
(a) Remove the 4 bolts, control retainer and gasket.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
HINT:
At the time of installation, install a new gasket.
(b) Remove the select return spring from the retainer.
7. A/T:
REMOVE UPPER COVER AND OIL DEFLECTOR
Remove the 4 bolts, upper cover, 2 gaskets and oil deflector.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
HINT:
At the time of installation, install a new gasket.
8. REMOVE FRONT COMPANION FLANGE
(a) Using a chisel and hammer, loosen the staked part of the
nut.
HINT:
At the time of installation, stake a new lock nut.
(b) Using SST to hold the flange, remove the companion
flange lock nut.
SST 09330−00021
Torque: 118 N·m (1,200 kgf·cm, 87 ft·lbf)
(c) Using SST, remove the companion flange.
SST 09950−40010
9. REMOVE REAR COMPANION FLANGE
Remove the rear companion flange in the same way as the front
companion flange.
HINT:
At the time of installation, please refer to the following items.
Front companion flange bolts are silver.
Rear companion flange bolts are black.

Downloaded from www.Manualslib.com manuals search engine TF0453
F02979
FIPG
TF0454
TF0455
Z14087
FIPG
− TRANSFERTRANSFER ASSEMBLY
TR−9
1996 TOYOTA T100 (RM449U)
10. REMOVE EXTENSION HOUSING
(a) Remove the 5 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the bolts.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a plastic hammer, tap the extension housing and
remove it.
HINT:
At the time of installation, please refer to the following items.
Remove any FIPG material and be careful not to drop oil
on the contacting surfaces of the extension housing.
Apply FIPG to the extension housing, as shown.
FIPG:
Part No.08826−00090,
THREE BOND 1281 or equivalent
11. REMOVE SPEEDOMETER DRIVE GEAR
(a) Remove the speedometer drive gear.
HINT:
At the time of installation, please refer to the following item.
Make sure to install the speedometer drive gear in the correct
direction.
(b) Using a magnetic finger, remove the ball from the rear out-
put shaft.
12. SEPARATE FRONT CASE AND REAR CASE
(a) Remove the 12 bolts.
Torque: 28 N·m (285 kgf·cm, 20 ft·lbf)
(b) Using a plastic hammer, tap the rear case and separate
the front case and rear case.
HINT:
At the time of installation, please refer to the following items.
Shift the high and low clutch sleeve to low side (rear side)
and assemble the front case and rear case.
Remove any FIPG material and be careful not to drop oil
on the contacting surfaces of the rear case.
Apply FIPG to the rear case, as shown.
FIPG:
Part No.08826−00090,
THREE BOND 1281 or equivalent

Downloaded from www.Manualslib.com manuals search engine TF0457
TF0458
TF0459
TF0619F03415
M/T:
A/T: TR−10
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
13. REMOVE STRAIGHT SCREW PLUGS, SPRINGS AND
LOCKING BALLS
(a) Using a hexagon wrench, remove the 2 straight screw
plugs.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the plugs.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a magnetic finger, remove the spring and ball from
the both holes.
14. REMOVE FRONT DRIVE FORK SHAFT, FORK,
SPRING AND STOPPER
(a) Using a pin punch and hammer, drive out the 2 slotted
spring pins.
HINT:
When the pin is removed from the front drive fork shaft, the shaft
will spring loose if the pin punch is removed, so keep the pin
punch inserted in the shaft hole.

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TF0622F03416
M/T:
A/T:
TF0460
− TRANSFERTRANSFER ASSEMBLY
TR−11
1996 TOYOTA T100 (RM449U)
HINT:
At the time of installation, please refer to the following item.
When installing the pin in the front drive fork shaft, push the
shaft towards the rear case and install the pin while the spring
is compressed.
(b) Hold the front drive fork shaft in place by hand, when re-
moving the pin punch.
(c) Remove the front drive fork shaft, spring and fork.
HINT:
At the time of installation, please refer to the following items.
Place the front drive shift fork into the groove of the clutch
sleeve.
Make sure to install the shift fork and stopper in the correct
direction.

Downloaded from www.Manualslib.com manuals search engine TF0462
TF0464
TF0465
TR−12
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
(d) Using a magnetic finger, remove the straight pin.
HINT:
At the time of installation, please refer to the following item.
Apply gear oil to the straight pin and insert it into the case hole.
15. REMOVE HIGH AND LOW FORK SHAFT, SHIFT FORK
AND STOPPER
HINT:
At the time of installation, please refer to the following items.
Place the high and low shift fork into the groove of the
clutch sleeve.
Make sure to install the shift fork in the correct direction.
16. REMOVE REAR OUTPUT SHAFT, DRIVEN
SPROCKET AND CHAIN
(a) Using a snap ring expander, remove the snap ring.
(b) Mount the rear case in the vise.
NOTICE:
Be careful not to damage the sealing surface.
(c) Using a plastic hammer, tap the rear case with pulling the
rear output shaft and driven sprocket.
HINT:
At the time of installation, please refer to the following item.
If necessary, heat the rear case to about 70°C (158°F).
(d) Remove the chain.