engine TOYOTA T100 1996 Factory Service Manual

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− SERVICE SPECIFICATIONSCLUTCH
SS−41
215 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH
SERVICE DATA
Pedal height from flower panel154.6 − 164.6 mm (6.087 − 6.480 in.)
Pedal height from asphalt sheet Extra Cab (4WD)150.1 − 160.1 mm (5.909 − 6.303 in.)
Pedal height from asphalt sheet Others153.1 − 163.1 mm (6.027 − 6.421 in.)
Push rod play at pedal top1.0 − 5.0 mm (0.039 − 0.197 in.)
Pedal freeplay5.0 − 15.0 mm (0.197 − 0.591 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch start switch ON−OFF Stroke5.0 ± 0.5 mm (0.197 ± 0.020 in.)
Slotted spring pin protrusion1.5 − 3.5 mm (0.059 − 0.138 in.)
Disc rivet head depth Min.0.3 mm (0.012 in.)
Disc runoutMax.0.8 mm (0.031 in.)
Flywheel runout Max.0.1 mm (0.004 in.)
Diaphragm spring finger wear Max. depth0.6 mm (0.024 in.)
Diaphragm spring finger wear Max. width5.0 mm (0.197 in.)
Diaphragm spring tip non−alignmentMax.0.5 mm (0.020 in.)

Downloaded from www.Manualslib.com manuals search engine SS07U−03
SS−42
− SERVICE SPECIFICATIONSCLUTCH
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Clutch line union1515511
Master cylinder installation nut131309
Bleeder plug1111 08
Clutch cover x Flywheel1919514
Release cylinder installation bolt121209
Release fork support 5VZ−FE4748035
Release fork support 3RZ−FE3940029

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− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (R150, R150F)
SS−43
217 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION(R150, R150F)
SERVICE DATA
Output shaft 1st gear journal diameterMin.38.860 mm (1.5299 in.)
Output shaft 2nd gear journal diameterMin.46.860 mm (1.8449 in.)
Output shaft 3rd gear journal diameterMin.37.860 mm (1.4905 in.)
Output shaft flange thicknessMin.4.70 mm (0.1850 in.)
Output shaft runoutMax.0.06 mm (0.0024 in.)
Gear thrust clearance 1st STD
Max.0.15−0.45 mm (0.0059−0.0177 in.)
0.50 mm (0.0197 in.)
Gear thrust clearance 2nd STD
Max.0.10−0.25 mm (0.0039−0.0098 in.)
0.30 mm (0.0118 in.)
Gear thrust clearance 3rd STD
Max.0.10−0.25 mm (0.0039−0.0098 in.)
0.30 mm (0.0118 in.)
Gear radial clearance 1st STD
Max.0.020−0.073 mm (0.0008−0.0029 in.)
0.160 mm (0.0063 in.)
Gear radial clearance 2nd STD
Max.0.015−0.068 mm (0.0006−0.0027 in.)
0.160 mm (0.0063 in.)
Gear radial clearance 3rd STD
Max.0.015−0.068 mm (0.0006−0.0027 in.)
0.160 mm (0.0063 in.)
Shift fork to hub sleeve clearanceMax.1.0 mm (0.039 in.)
Synchronizer ring to gear clearanceMin.0.8 mm (0.031 in.)
Input shaft snap ring thickness
Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.10−2.15 mm (0.0827−0.0846 in.)
2.15−2.20 mm (0.0846−0.0866 in.)
2.20−2.25 mm (0.0866−0.0886 in.)
2.25−2.30 mm (0.0886−0.0906 in.)
2.30−2.35 mm (0.0906−0.0925 in.)
2.35−2.40 mm (0.0925−0.0945 in.)
2.40−2.45 mm (0.0945−0.0965 in.)
Output shaft snap ring thickness
Clutch hub No.1 Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.30−2.35 mm (0.0906−0.0925 in.)
2.35−2.40 mm (0.0925−0.0945 in.)
2.40−2.45 mm (0.0945−0.0965 in.)
2.45−2.50 mm (0.0965−0.0984 in.)
2.50−2.55 mm (0.0984−0.1004 in.)
2.55−2.60 mm (0.1004−0.1024 in.)
2.60−2.65 mm (0.1024−0.1043 in.)
Output shaft snap ring thickness
Clutch hub No.2 Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
1.80−1.85 mm (0.0709−0.0728 in.)
1.85−1.90 mm (0.0728−0.0748 in.)
1.90−1.95 mm (0.0748−0.0768 in.)
1.95−2.00 mm (0.0768−0.0787 in.)
2.00−2.05 mm (0.0787−0.0807 in.)
2.05−2.10 mm (0.0807−0.0827 in.)
2.10−2.15 mm (0.0827−0.0846 in.)

Downloaded from www.Manualslib.com manuals search engine SS−44
− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (R150, R150F)
218 Author: Date:
1996 TOYOTA T100 (RM449U) Output shaft snap ring thickness
Rear Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
Mark H
Mark J
Mark K
Mark L
Mark M
Mark N
Mark P
Mark Q
Mark R
Mark S
2.65−2.70 mm (0.1043−0.1063 in.)
2.70−2.75 mm (0.1063−0.1083 in.)
2.75−2.80 mm (0.1083−0.1102 in.)
2.80−2.85 mm (0.1102−0.1122 in.)
2.85−2.90 mm (0.1122−0.1142 in.)
2.90−2.95 mm (0.1142−0.1161 in.)
2.95−3.00 mm (0.1161−0.1181 in.)
3.00−3.05 mm (0.1181−0.1201 in.)
3.05−3.10 mm (0.1201−0.1220 in.)
3.10−3.15 mm (0.1220−0.1240 in.)
3.15−3.20 mm (0.1240−0.1260 in.)
3.20−3.25 mm (0.1260−0.1280 in.)
3.25−3.30 mm (0.1280−0.1299 in.)
3.30−3.35 mm (0.1299−0.1319 in.)
3.35−3.40 mm (0.1319−0.1339 in.)
3.40−3.45 mm (0.1339−0.1358 in.)
3.45−3.50 mm (0.1358−0.1378 in.)
Counter gear roller bearing journal diameterMin.27.860 mm (1.0968 in.)
Counter 5th gear thrust clearance STD
Max.0.10−0.35 mm (0.0039−0.0138 in.)
0.40 mm (0.0157 in.)
Counter 5th radial clearance STD
Max.0.015−0.068 mm (0.0006−0.0027 in.)
0.160 mm (0.0063 in.)
Reverse idler gear radial clearance STD
Max.0.040−0.082 mm (0.0016−0.0032 in.)
0.130 mm (0.0051 in.)
Reverse idler gear to shift arm clearance STD
Max.0.05−0.35 mm (0.0020−0.0138 in.)
0.50 mm (0.0197 in.)
Counter gear snap ring thickness
Front Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
2.00−2.05 mm (0.0787−0.0807 in.)
2.05−2.10 mm (0.0807−0.0827 in.)
2.10−2.15 mm (0.0827−0.0846 in.)
2.15−2.20 mm (0.0846−0.0866 in.)
2.20−2.25 mm (0.0866−0.0886 in.)
2.25−2.30 mm (0.0886−0.0906 in.)
Counter gear snap ring thickness
Rear Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.80−2.85 mm (0.1102−0.1122 in.)
2.85−2.90 mm (0.1122−0.1142 in.)
2.90−2.95 mm (0.1142−0.1161 in.)
2.95−3.00 mm (0.1161−0.1181 in.)
3.00−3.05 mm (0.1181−0.1201 in.)
3.05−3.10 mm (0.1201−0.1220 in.)
3.10−3.15 mm (0.1220−0.1240 in.)
Oil seal drive in depth
Speedometer driven gear
Front bearing retainer (from retainer end)
Extension housing
Transfer adaptor
25 mm (0.98 in.)
11.7 ± 0.5 mm (0.461 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
45.6 ± 0.5 mm (1.795 ± 0.020 in.)

Downloaded from www.Manualslib.com manuals search engine SS07W−01
− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (R150, R150F)
SS−45
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transmission x Engine7273053
Stiffener plate x Engine (4WD)3738027
Stiffener plate x Transmission (4WD)3738027
Starter x Transmission3940029
Engine rear mounting x Transmission6566048
Rear end plate x Transmission (2WD)1818513
Clutch release cylinder x Transmission121209
Front exhaust pipe x TWC4849035
Front exhaust pipe support bracket4445033
Front exhaust pipe x Exhaust manifold6263046
Crossmember x Engine rear mounting (4WD)1818013
Engine rear mounting bracket x Engine rear mounting (2WD)1818013
Engine rear mounting bracket x Frame (2WD)5859043
Crossmember x Frame (4WD)9597070
Transmission x Transfer (4WD)3738027
Reverse shift arm bracket set bolt1818513
Rear bearing retainer x Intermediate plate1818513
Shift fork x Shift fork shaft2020014
Straight screw plug1919014
Front bearing retainer x Transmission case1717012
Transmission case x Transfer adaptor3738027
Transmission case x Extension housing3738027
Shift lever housing set bolt3839028
Clutch housing x Transmission case3637027
Oil receiver x Extension housing1111 58
Back−up light switch4445032
Restrict pin3738027
Control shift lever retainer x Transfer adaptor1818513
Control shift lever retainer x Extension housing1818513
Filler and drain plug3738027
Speedometer driven gear (2WD)1111 58

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SS−46
− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (W59)
220 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION (W59)
SERVICE DATA
Output shaft 2nd gear journal diameterMin.42.975 mm (1.6919 in.)
Output shaft 3rd gear journal diameterMin.31.969 mm (1.2586 in.)
Output shaft flange thicknessMin.5.60 mm (0.2205 in.)
Output shaft runoutMax.0.06 mm (0.0024 in.)
1st gear inner race flange thicknessMin.4.78 mm (0.1881 in.)
1st gear inner race outer diameterMin.42.975 mm (1.6919 in.)
Counter gear bearing journal diameterMin.29.950 mm (1.1791 in.)
Counter 5th gear journal diameterMin.26.975 mm (1.0620 in.)
1st, 2nd and 3rd gear thrust clearance STD
Max.0.10 − 0.25 mm (0.0039 − 0.0098 in.)
0.30 mm (0.0118 in.)
Counter 5th gear thrust clearance STD
Max.0.10 − 0.41 mm (0.0039 − 0.0161 in.)
0.46 mm (0.0181 in.)
1st, 2nd and counter 5th gear radial clearance STD
Max.0.009 − 0.060 mm (0.0004 − 0.0024 in.)
0.150 mm (0.0059 in.)
3rd gear radial clearance STD
Max.0.015 − 0.066 mm (0.0006 − 0.0026 in.)
0.200 mm (0.0079 in.)
Reverse idler gear radial clearance STD
Max.0.041 − 0.074 mm (0.0016 − 0.0029 in.)
0.194 mm (0.0076 in.)
Reverse idler gear to shift arm shoe clearance STD
Max.0.20 − 0.41 mm (0.0080 − 0.0161 in.)
0.90 mm (0.0354 in.)
Shift fork to hub sleeve clearanceMax.1.0 mm (0.039 in.)
Synchronizer ring to 1st and 4th gear clearanceMin.0.5 mm (0.020 in.)
Synchronizer ring to 2nd and 3rd gear clearanceMin.0.7 mm (0.028 in.)
Input shaft snap ring thickness
Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Mark 11
Mark 12
2.05 − 2.10 mm (0.0807 − 0.0827 in.)
2.10 − 2.15 mm (0.0827 − 0.0846 in.)
2.15 − 2.20 mm (0.0846 − 0.0866 in.)
2.20 − 2.25 mm (0.0866 − 0.0886 in.)
2.25 − 2.30 mm (0.0886 − 0.0906 in.)
2.30 − 2.35 mm (0.0906 − 0.0925 in.)
2.35 − 2.40 mm (0.0925 − 0.0945 in.)
Output shaft snap ring thickness
No.2 clutch hub Mark C−1
Mark D
Mark 11
Mark 12
Mark 13
Mark 14
Mark 15
1.75 − 1.80 mm (0.0689 − 0.0709 in.)
1.80 − 1.85 mm (0.0709 − 0.0728 in.)
1.86 − 1.91 mm (0.0732 − 0.0752 in.)
1.92 − 1.97 mm (0.0756 − 0.0776 in.)
1.98 − 2.03 mm (0.0780 − 0.0799 in.)
2.04 − 2.09 mm (0.0803 − 0.0823 in.)
2.10 − 2.15 mm (0.0827 − 0.0846 in.)
Output shaft snap ring thickness
Rear bearing Mark 8
Mark 9
Mark 10
Mark 11
Mark 12
Mark 13
Mark 14
Mark 15
2.31 − 2.36 mm (0.0909 − 0.0929 in.)
2.37 − 2.42 mm (0.0933 − 0.0953 in.)
2.43 − 2.48 mm (0.0957 − 0.0976 in.)
2.49 − 2.54 mm (0.0980 − 0.1000 in.)
2.55 − 2.60 mm (0.1004 − 0.1024 in.)
2.61 − 2.66 mm (0.1028 − 0.1047 in.)
2.68 − 2.73 mm (0.1055 − 0.1075 in.)
2.74 − 2.79 mm (0.1079 − 0.1098 in.)

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSMANUAL TRANSMISSION (W59)
SS−47
221 Author: Date:
1996 TOYOTA T100 (RM449U) Output shaft snap ring thickness
Reverse gear Mark 5
Mark 11
Mark 12
Mark 13
Mark 14
Mark 15
Mark 16
Mark 17
Mark 18
Mark 19
Mark 20
Mark 21
Mark 22
Mark 23
2.25 − 2.30 mm (0.0886 − 0.0906 in.)
2.30 − 2.35 mm (0.0906 − 0.0925 in.)
2.35 − 2.40 mm (0.0925 − 0.0945 in.)
2.40 − 2.45 mm (0.0945 − 0.0965 in.)
2.45 − 2.50 mm (0.0965 − 0.0984 in.)
2.50 − 2.55 mm (0.0984 − 0.1004 in.)
2.55 − 2.60 mm (0.1004 − 0.1024 in.)
2.61 − 2.66 mm (0.1028 − 0.1047 in.)
2.67 − 2.72 mm (0.1051 − 0.1071 in.)
2.73 − 2.78 mm (0.1075 − 0.1094 in.)
2.79 − 2.84 mm (0.1098 − 0.1118 in.)
2.85 − 2.90 mm (0.1122 − 0.1142 in.)
2.91 − 2.96 mm (0.1146 − 0.1165 in.)
2.97 − 3.02 mm (0.1169 − 0.1189 in.)
Coutner gear snap ring thickness
Front bearing Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.05 − 2.10 mm (0.0807 − 0.0827 in.)
2.10 − 2.15 mm (0.0827 − 0.0846 in.)
2.15 − 2.20 mm (0.0846 − 0.0866 in.)
2.20 − 2.25 mm (0.0866 − 0.0886 in.)
2.25 − 2.30 mm (0.0886 − 0.0906 in.)
2.30 − 2.35 mm (0.0906 − 0.0925 in.)
2.35 − 2.40 mm (0.0925 − 0.0945 in.)
Counter gear snap ring thickness
No.3 clutch hub Mark 2
Mark 3
Mark 4
Mark 5
2.06 − 2.11 mm (0.0811 − 0.0831 in.)
2.12 − 2.17 mm (0.0835 − 0.0854 in.)
2.18 − 2.23 mm (0.0858 − 0.0878 in.)
2.24 − 2.29 mm (0.0882 − 0.0902 in.)
Counter gear snap ring thickness
Rear bearing Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
Mark 7
1.90 − 1.95 mm (0.0748 − 0.0768 in.)
1.96 − 2.01 mm (0.0772 − 0.0791 in.)
2.02 − 2.07 mm (0.0795 − 0.0815 in.)
2.08 − 2.13 mm (0.0819 − 0.0839 in.)
2.14 − 2.19 mm (0.0843 − 0.0862 in.)
2.20 − 2.25 mm (0.0866 − 0.0886 in.)
2.26 − 2.31 mm (0.0890 − 0.0909 in.)
Oil seal drive in depth
Front bearing retainer (from retainer end)
Extension housing
Speedometer drive gear
12.2 ± 0.5 mm (0.480 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
25 mm (0.98 in.)

Downloaded from www.Manualslib.com manuals search engine SS060−03
SS−48
− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (W59)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transmission x Engine7273053
Transmission x Starter3940029
Rear end plate x Clutch housing3738027
Shift fork set bolt2020014
Straight screw plug2525018
Reverse idler gear shaft stopper bolt2525018
Oil separator x Intermediate plate1818513
Front bearing retainer set bolt2525018
Extension housing x Intermediate plate3738027
Restrict pin4041030
Shift lever housing x Shift and select lever shaft3940029
Control shift lever retainer x Extension housing1818513
Drain and filler plugs3738027
Back−up light switch4041030
Clutch housing x Transmission case3738027
Rear bearing retainer x Intermediate plate1818513
Speedometer driven gear131309

Downloaded from www.Manualslib.com manuals search engine SS089−02
− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
SS−49
223 Author: Date:
1996 TOYOTA T100 (RM449U)
AUTOMATIC TRANSMISSION
SERVICE DATA
Line pressure (Wheel locked)
(3RZ−FE)
Engine idling
D position
R position
at stall (Throttle valve fully opened)
D position
R position
(5VZ−FE)
Engine idling
D position
R position
at stall (Throttle valve fully opened)
D position
R position
363 − 422 kPa (3.7 − 4.2 kgf/cm2, 53 − 61 psi)
490 − 588 kPa (5.0 − 6.0 kgf/cm2, 71 − 85 psi)
932 − 1,177 kPa (9.5 − 12.0 kgf/cm
2, 135 − 171 psi)
1,294 − 1,638 kPa (13.2 − 16.7 kgf/cm2, 188 − 238 psi)
363 − 422 kPa (3.7 − 4.2 kgf/cm
2, 53 − 61 psi)
608 − 696 kPa (6.2 − 7.1 kgf/cm2, 88 − 101 psi)
902 − 1,147 kPa (9.2 − 11.7 kgf/cm
2, 131 − 166 psi)
1,432 − 1,942 kPa (14.6 − 19.8 kgf/cm2, 208 − 282 psi)
Engine stall revolution (D and R positions) 3RZ−FE
5VZ−FE1,950 ± 150 rpm
2,150 ± 150 rpm
Time lag N → D position
N → R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed
(A/C OFF and N position)
700 ± 50 rpm
Throttle cable adjustment
(Throttle valve fully opened)Between boot end face and inner cable stopper
0 − 1 mm (0 − 0.04 in.)
Drive plate runoutMax.
Torque converter runoutMax.
Torque converter installation distance 3R−FE
5VZ−FE0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
More than 31.75 mm (1.2500 in.)
More than 17.95 mm (0.7067 in.)
Speedometer driven gear oil seal drive in depth 3RZ−FE
5VZ−FE20 mm (0.79 in.)
20 mm (0.79 in.)
Lock−up point
(3RZ−FE / A340E)
D position
(Throttle valve opening 5%) Lock−up ON
Lock−up OFF
(5VZ−FE / A340E)
D position
(Throttle valve opening 5%) Lock−up ON
Lock−up OFF
(5VZ−FE / A340F)
(Throttle valve opening 5%) Lock−up ON
Lock−up OFF
83 − 88 km/h (52 − 55 mph)
70 − 75 km/h (44 − 47 mph)
79 − 84 km/h (49 − 52 mph)
72 − 77 km/h (45 − 48 mph)
75 − 80 km/h (47 − 50 mph)
68 − 73 km/h (42 − 45 mph)

Downloaded from www.Manualslib.com manuals search engine SS−50
− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
224 Author: Date:
1996 TOYOTA T100 (RM449U) Shift schedule
(3RZ−FE / A340E)
D position
(Throttle valve fully opened) 1 → 2
2 → 3
3 → O/D
O/D → 3
3 → 2
2 → 1
(Throttle valve fully closed) 3 → O/D
O/D → 3
2 position
(Throttle valve fully opened) 1 → 2
3 → 2
2 → 1
L position
(Throttle valve fully opened) 2 →1
(5VZ−FE / A340E)
D position
(Throttle valve fully opened) 1 → 2
2 → 3
3 → O/D
O/D → 3
3 → 2
2 → 1
(Throttle valve fully closed) 3 → O/D
O/D → 3
2 position
(Throttle valve fully opened) 1 → 2
3 → 2
2 → 1
L position
(Throttle valve fully opened) 2 →1
(5VZ−FE / A340F)
D position
(Throttle valve fully opened) 1 → 2
2 → 3
3 → O/D
O/D → 3
3
→ 2
2 → 1
(Throttle valve fully closed) 3 → O/D
O/D → 3
2 position
(Throttle valve fully opened) 1 → 2
3 → 2
2 → 1
L position
(Throttle valve fully opened) 2 →1
55 − 60 km/h (34 − 37 mph)
99 − 108 km/h (62 − 67 mph)
127 − 136 km/h (79 − 85 mph)
120 − 130 km/h (75 − 81 mph)
92 − 98 km/h (57 − 61 mph)
44 − 48 km/h (27 − 30 mph)
34 − 39 km/h (21 − 24 mph)
25 − 30 km/h (16 − 19 mph)
55 − 60 km/h (34 − 37 mph)
110 − 120 km/h (68 − 75 mph)
44 − 48 km/h (27 − 30 mph)
53 − 58 km/h (33 − 36 mph)
57 − 62 km/h (35 − 39 mph)
108 − 117 km/h (67 − 73 mph)
146 − 155 km/h (91 − 96 mph)
139 − 148 km/h (86 − 92 mph)
99 − 108 km/h (62 − 67 mph)
46 − 51 km/h (29 − 32 mph)
44 − 49 km/h (27 − 30 mph)
22 − 27 km/h (14 − 17 mph)
57
− 62 km/h (35 − 39 mph)
115 − 124 km/h (71 − 77 mph)
46 − 51 km/h (29 − 32 mph)
52 − 58 km/h (32 − 36 mph)
55 − 59 km/h (35 − 39 mph)
103 − 111 km/h (64 − 69 mph)
139 − 147 km/h (86 − 91 mph)
133 − 141 km/h (83 − 88 mph)
95 − 103 km/h (59 − 64 mph)
44 − 48 km/h (27 − 30 mph)
42 − 47 km/h (26 − 29 mph)
21 − 26 km/h (13 − 16 mph)
55 − 59 km/h (34 − 37 mph)
110 − 118 km/h (68 − 73 mph)
44 − 48 km/h (27 − 30 mph)
53 − 58 km/h (33 − 36 mph)