replace manual transmission TOYOTA T100 1996 Factory User Guide

Downloaded from www.Manualslib.com manuals search engine PP3LO−01
PP−86
− PREPARATIONPROPELLER SHAFT
135 Author: Date:
1996 TOYOTA T100 (RM449U)
PROPELLER SHAFT
SST (Special Service Tools)
09325−40010Transmission Oil PlugTransmission to prevent oil leakage
09330−00021Companion Flange Holding ToolCompanion flange holding
09332−25010Universal Joint Bearing Remover
& ReplacerSpider bearing removal and installa-
tion

Downloaded from www.Manualslib.com manuals search engine PP3K7−01
PP−88
− PREPARATIONSUSPENSION AND AXLE
137 Author: Date:
1996 TOYOTA T100 (RM449U)
SUSPENSION AND AXLE
SST (Special Service Tools)
09223−56010Crankshaft Rear Oil Seal
ReplacerRear axle
09226−10010Crankshaft Front & Rear Bearing
ReplacerFront differential
09308−00010Oil Seal PullerFront axle (4WD)
Front differential
Rear axle
Rear differential
09316−12010Transfer Bearing ReplacerRear differential
09316−20011Transfer Bearing ReplacerFront differential
09316−60011Transmission & Transfer Bearing
ReplacerFront deifferentian
Rear axle
(09316−00041)Replacer ”C”Front differential
(09316−00051)Replacer ”D”Rear axle
09330−00021Companion Flange Holding ToolFront differential
Rear differential
09350−20015TOYOTA Automatic Transmission
Tool SetFront differential
(09369−20040)Piston Spring Compressor Set
09308−10010Oil Seal PullerFront differential
Rear differential

Downloaded from www.Manualslib.com manuals search engine AT3417
OK if hot
Add if hot DI−270
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
HINT:
There is no O/D up−shift and lock−up in the 2 position.
(2) Check engine braking.
While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine
braking effect.
Evaluation:
ProblemPossible cause
If there is no engine braking effect2nd coast brake defective
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up−shift and
down−shift.
(c) L position test
Shift into the 2 position and fully depress the accelerator pedal and check the following points:
(1) Check no up−shift.
While running in the L position, check that there is no up−shift to 2nd gear.
(2) Check engine braking.
While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
Evaluation:
ProblemPossible cause
If there is no engine braking effect1st and reverse brake is defective
(3) Check for abnormal noises during acceleration and deceleration.
(d) R position test
Shift into the R position and fully depress the accelerator pedal and check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from personnel and obstruction.
(e) P position test
Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking
brake. Then, check to see that the parking lock pawl holds the vehicle in place.
5. BASIC INSPECTION
(a) Check the fluid level.
HINT:
Drive the vehicle so that the engine and transmission are
at normal operating temperature.
Fluid temp.: 70 − 80°C (158 − 176°F)
Only use the COOL range on the dipstick as a rough refer-
ence when the fluid is replaced or the engine does not
run.
(1) Park the vehicle on a level surface and set the park-
ing brake.
(2) With the engine idling and the brake pedal de-
pressed, shift the shift lever into all positions from P
to L position and return to P position.
(3) Pull out the dipstick and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range.

Downloaded from www.Manualslib.com manuals search engine AT1347
AT6683
AT3417
OK if hot
Add if hot
AT4252
0 − 1 mm (0 − 0.04 in.)
Q03104No.1 Gear Shifting Rod
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−271
1996 TOYOTA T100 (RM449U)
If the level is at the low side, add new fluid.
Fluid type: ATF DEXRON®II
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the ATF.
(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
(3) With the engine OFF, add new fluid through the oil
filler pipe.
Fluid type: ATF DEXRON®II
Capacity:
A340E: 1.6 liters (1.7 US qts, 1.4 Imp. qts)
A340F: 2.0 liters (2.1 US qts, 1.8 Imp. qts)
(4) Start the engine and shift the shift lever into all posi-
tions from P to L position and then shift into P posi-
tion.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature, 70 − 80°C (158 − 176°F), and add as nec-
essary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transmission.
If there are leaks, it is necessary to repair or replace O−
rings, FIPGs, oil seals, plugs or other parts.
(e) INSPECT AND ADJUST THROTTLE CABLE
(1) Check that the accelerator pedal is fully released.
(2) Check that the inner cable is not slack.
(3) Measure the distance between the outer cable end
and stopper on the cable.
Standard distance: 0 − 1 mm (0 − 0.04 in.)
If the distance is not standard, adjust the cable by the adjusting
nuts.
(f) Inspect and adjust the shift lever position.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator is not aligned with the correct position.
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures.
(1) Remove the nut on the No.1 gear shifting rod.
(2) Push the No.1 gear shifting rod fully downward.

Downloaded from www.Manualslib.com manuals search engine DI0VJ−02
DI−282
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
PROBLEM SYMPTOMS TABLE
If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the
circuits for each symptom in the order given in the charts on the following pages and proceed to the page
given for troubleshooting.
The Matrix Chart is divided into 3 chapters.
Chapter 1: Electronic Circuit Matrix Chart
Chapter 2: On−vehicle Repair Matrix Chart
Chapter 3: Off−vehicle Repair Matrix Chart
If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow
chart for each circuit, proceed to the circuit with the next highest number in the table to continue
the check.
If the trouble still occurs even though there are no abnormalities in any of the other circuits, then
check and replace the ECM.
Chapter 1: Electronic Circuit Matrix Chart
SymptomSuspect AreaSee page
No up−shift
(A particular gear, from 1st to 3rd gear, is not up−shifted)1. ECMDI−279
No up−shift (3rd → O/D)
1. O/D main switch & O/D OFF indicator light circuit
2. O/D cancel signal circuit
3. ECMDI−311
DI−309
DI−279
No down−shift (O/D → 3rd)1. ECMDI−279
No down−shift
(A particular gear, from 1st to 3rd gear, is not up−shifted)1. ECMDI−279
No lock−up1. Stop light swich circuit
2. ECMDI−316
DI−279
No lock−up off1. Stop light swich circuit
2. ECMDI−316
DI−279
Shift point too high or too low1. ECMDI−279
Up−shift to O/D from 3rd while O/D main switch is OFF1. O/D main switch & O/D OFF indicator light circuit
2. ECMDI−311
DI−279
Up−shift to O/D from 3rd while engine is cold1. ECMDI−279
No kick−down1. ECMDI−279
Engine stalls when starting off or stopping1. Stop light swich circuit
2. ECMDI−316
DI−279

Downloaded from www.Manualslib.com manuals search engine Q07637
DI−288
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
INSPECTION PROCEDURE
1 Check ATF Temperature Sensor.
PREPARATION:
Remove the ATF temperature sensor.
CHECK:
Measure resistance between terminals of ATF temperature
sensor at 20°C (68°F) and 110°C (230°F).
OK:
Resistance:
20°C (68°F): Approx. 13.0 kΩ
11 0°C (230°F): Approx. 800 Ω
NG Replace ATF temperature sensor.
OK
2 Check harness and connector between ATF temperature sensor and ECM
(See page IN−26).
NG Repair or replace harness or connector.
OK
Check and replace ECM.

Downloaded from www.Manualslib.com manuals search engine Q07640
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−289
1996 TOYOTA T100 (RM449U)
DTC P0750, P0755 Shift Solenoid A/B Malfunction (Shift
Solenoid Valve No.1/No.2)
SYSTEM DESCRIPTION
The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd or O/D
gear).
Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical
trouble of the shift solenoid valves and valve body.
DTC No.DTC Detecting ConditionTrouble Area
P0750
P0755During normal driving, gear required by ECM does not match
actual gear
(2 trip detection logic)Shift solenoid valve No.1/No.2 is stuck open or closed
Valve body is blocked up or stuck
HINT:
Check the shift solenoid valve No.1 when DTC P0750 is output and check shift solenoid valve No.2 when
DTC P0755 is output.
INSPECTION PROCEDURE
1 Check shift solenoid valve No.1 or No.2 operation.
PREPARATION:
(a) Remove the oil pan.
(b) Remove the shift solenoid valve No.1 or No.2.
CHECK:
(a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air,
check that the solenoid valve does not leak air.
(b) When battery positive voltage is supplied to the shift sole-
noid valve, check that the solenoid valve opens.
NG Replace shift solenoid valve No.1 or No.2.
OK
2 Check valve body (See page DI−282).
NG Repair or replace valve body.
OK
Repair or replace transmission (See page
AT−26, AT−33).
DI0VM−01

Downloaded from www.Manualslib.com manuals search engine Q06970
ECM
B+
B+ S1
S2 E2
E2 Transmission
Shift Solenoid
Valve No.1
Shift Solenoid
Valve No.21
211
17*
1
*2
*1: 3RZ−FE
*2: 5VZ−FEW
B−W W
BE7
E7 10
9*
2*1
B−W
B−W
To Cruise Control ECU
Q07641
Q07642D00006
3RZ−FE
5VZ−FES2
S1
S2
S1
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−291
1996 TOYOTA T100 (RM449U)
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Measure resistance between terminal S1 or S2 of ECM connector and body
ground.
PREPARATION:
Disconnect the connector from the ECM.
CHECK:
Measure resistance between terminal S1 or S2 of ECM connec-
tor and body ground.
OK:
Resistance: 11 − 15 Ω
OK Check and replace ECM.
NG

Downloaded from www.Manualslib.com manuals search engine Q07643
Q07644
Q05336
D00007
3RZ−FE
5VZ−FES2
S1 S2
S1
S1
S2
S2
S1
S1
DI−292
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
2 Check harness and connector between ECM connector and automatic transmis-
sion solenoid connector.
PREPARATION:
Disconnect the solenoid connector from the automatic trans-
mission.
CHECK:
Check the harness and connector between terminal S1 or S2
of ECM connector and terminal S1 or S2 of solenoid connector.
OK:
There is no open and no short circuit.
NG Repair or replace harness or connector.
OK

Downloaded from www.Manualslib.com manuals search engine Q07645
Q07646D00005
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−293
1996 TOYOTA T100 (RM449U)
3 Check shift solenoid valve No.1 or No.2.
PREPARATION:
(a) Remove the oil pan.
(b) Remove the shift solenoid valve No.1 or No.2.
CHECK:
(a) Measure resistance between solenoid connector and so-
lenoid body.
(b) Connect positive lead to terminal of solenoid connector,
negative lead to solenoid body.
OK:
(a) Resistance: 11 − 15 Ω
(b) The solenoid makes an operating noise.
NG Replace solenoid valve.
OK
Repair or replace solenoid wire.