replace manual transmission TOYOTA T100 1996 Factory Repair Manual

Downloaded from www.Manualslib.com manuals search engine MT03Y−01
D00875
D00878
B
A
D00879
Q00914
MT−32
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT COUNTER 5TH GEAR RADIAL CLEAR-
ANCE
(a) Install the spacer, counter 5th gear and needle roller bear-
ing to the counter gear.
(b) Using a dial indicator, measure the counter 5th gear radial
clearance.
Standard clearance:
0.009 − 0.060 mm (0.0004 − 0.0024 in.)
Maximum clearance:
0.150 mm (0.0059 in.)
If the clearance exceeds the maximum, replace the counter
gear, needle roller bearing or counter 5th gear.
2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter
shaft journal.
Minimum diameter:
Part A: 26.975 mm (1.0620 in.)
Part B: 29.950 mm (1.1791 in.)
If the outer race is less than the minimum, replace the counter
gear.
3. INSPECT REVERSE IDLER GEAR RADIAL CLEAR-
ANCE
Using a dial indicator, measure the reverse idler gear radial
clearance.
Standard clearance:
0.041 − 0.074 mm (0.0016 − 0.0029 in.)
Maximum clearance:
0.194 mm (0.0076 in.)
If the clearance exceeds the maximum, replace the gear or
shaft.
4. INSPECT REVERSE IDLER GEAR AND SHIFT ARM
SHOE CLEARANCE
Using a feeler gauge, measure the clearance between the re-
verse idler gear and shift arm shoe.
Standard clearance:
0.20 − 0.41 mm (0.0079 − 0.0161 in.)
Maximum clearance:
0.90 mm (0.0354 in.)
If the clearance exceeds the maximum, replace the shift arm
shoe or reverse idler gear.

Downloaded from www.Manualslib.com manuals search engine Q04038
Q04011
WM0066
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
MT−33
1996 TOYOTA T100 (RM449U)
5. INSPECT 5TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer pull ring, cone ring and outer ring
to the 5th gear.
(c) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
6. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeves and shift forks.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

Downloaded from www.Manualslib.com manuals search engine MT03Z−01
WM0073
SST
Q06319
SST
Socket Wrench
RM0013
Socket Wrench
D00876
WM0079
MT−34
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. IF NECESSARY, REPLACE COUNTER GEAR FRONT
BEARING AND SIDE RACE
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, press out the bearing.
SST 09950−00020
(c) Check the side race for wear or damage.
(d) If necessary, remove the side race.
Using SST and a socket wrench, remove the side race.
SST 09950−40010
(e) Using a socket wrench and press, install a new bearing,
side race and inner race.
(f) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.05 − 2.10 (0.0807 − 0.0827)
B2.10 − 2.15 (0.0827 − 0.0846)
C2.15 − 2.20 (0.0846 − 0.0866)
D2.20 − 2.25 (0.0866 − 0.0886)
E2.25 − 2.30 (0.0886 − 0.0906)
F2.30 − 2.35 (0.0906 − 0.0925)
(g) Using a snap ring expander, install the snap ring.
2. IF NECESSARY, REPLACE COUNTER GEAR CENTER
BEARING
(a) Remove the bearing from the counter gear.
(b) Install a new bearing on the counter gear.
HINT:
Engage the roller cages.

Downloaded from www.Manualslib.com manuals search engine MT042−01
Q07368
SST
− MANUAL TRANSMISSION (W59)FRONT BEARING RETAINER OIL SEAL
MT−39
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 press, install a new oil seal.
SST 09950−60010 (09951−00440), 09950−70010
(09951−07150)
Drive in depth: 12.2 ± 0.5 mm (0.480 ± 0.020 in.)

Downloaded from www.Manualslib.com manuals search engine MT044−01
Q04410
D00877
Reverse Restrict PinSlotted
Spring Pin
WM0085
Q07553
SST
− MANUAL TRANSMISSION (W59)EXTENSION HOUSING
MT−41
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Remove the reverse restrict pin.
(1) Using a hexagon wrench, remove the screw plug.
(2) Using a pin punch and hammer, drive out the slotted
spring pin.
(3) Pull off the lever housing and slide out the shaft.
(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 lever housing.
(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) Install and torque the screw plug.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
2. IF NECESSARY, REPLACE REAR BEARING OUTER
RACE
(a) Using 2 screwdrivers, remove the snap ring.
(b) Using SST, remove the outer race.
SST 09308−00010

Downloaded from www.Manualslib.com manuals search engine Q07370
SST
WM0110
SST
Q07371
SST MT−42
− MANUAL TRANSMISSION (W59)EXTENSION HOUSING
1996 TOYOTA T100 (RM449U)
(c) Using SST, install a new outer race.
SST 09950−60010 (09951−00560), 09950−70010
(09951−07150)
(d) Using a screwdriver, install the snap ring.
3. IF NECESSARY, REPLACE EXTENSION HOUSING
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09308−00010 or 09308−10010 w/ output shaft
installed
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00560), 09950−70010
(09951−07150)
Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)

Downloaded from www.Manualslib.com manuals search engine AT024−01
− AUTOMATIC TRANSMISSIONSHIFT LOCK SYSTEM
AT−19
1360 Author: Date:
1996 TOYOTA T100 (RM449U)
SHIFT LOCK SYSTEM
ON−VEHICLE INSPECTION
CHECK SHIFT LOCK SYSTEM
(a) With depressing the brake pedal, check that the tip of the parking lock cable protrudes from the pedal
bracket.
(b) Set the shift position to the P position. With the brake pedal depressed, check the select lock cancel.
(c) Check that the lock pin has no unusual operation sound.
(d) Remove the center cluster finish lower panel. (See page BO−36)
(1) Check that the sliding rod is protruded when the ignition key plate is turned from LOCK position
to ACC position.
(2) Check that the sliding rod is released when the ignition key plate is turned to LOCK position.
If the key interlock solenoid operation is defective, replace the key cylinder.

Downloaded from www.Manualslib.com manuals search engine AT02B−02
Q06797
Q06962
3RZ−FE AT−28
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340E)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE ATF LEVEL GAUGE
2. REMOVE ENGINE UNDER COVER
3. DISCONNECT THROTTLE CABLE
(a) Loosen the nut and disconnect the cable.
(b) Remove the throttle cable from the clamps.
4. 5VZ−FE:
REMOVE NO.1 THROTTLE CABLE CLAMP
Remove the 2 nuts and No.1 throttle cable clamp.
5. JACK UP VEHICLE
6. REMOVE OIL FILLER PIPE
Remove the bolt and oil filler pipe with the O−ring.
HINT:
At the time of reassembly, please refer to the following item.
Replace used O−ring with a new one.
7. REMOVE PROPELLER SHAFT (See page PR−3)
8. 3RZ−FE:
REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 bolts and retainer.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(c) Loosen the clamp bolt and disconnect the clamp from the
support bracket.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(d) Remove the 2 bolts and support bracket.
Torque: 71 N·m (730 kgf·cm, 53 ft·lbf)
(e) Remove the 3 nuts, front exhaust pipe and 3 gaskets.
Torque: 62 N·m (630 kgf·cm, 40 ft·lbf)
HINT:
At the time of reassembly, please refer to the following item.
Replace the used 3 gaskets with new ones.

Downloaded from www.Manualslib.com manuals search engine Q06796
5VZ−FE
Q06806
Z18883
A
B
C
Q06986
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340E)
AT−29
1996 TOYOTA T100 (RM449U)
9. 5VZ−FE:
REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 bolts and retainer.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(c) Remove the 3 bolts and support bracket.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
(d) Remove the 3 nuts, front exhaust pipe and 3 gaskets.
Torque: 62 N·m (630 kgf·cm, 40 ft·lbf)
HINT:
At the time of reassembly, please refer to the following item.
Replace the used 3 gaskets with new ones.
10. DISCONNECT SPEEDOMETER CABLE
(a) Loosen the serrated collar with pliers. Do not lose the felt
dust protector and washer.
(b) Disconnect the cable.
11. DISCONNECT NO.2 VEHICLE SPEED SENSOR CON-
NECTOR AND SOLENOID CONNECTOR
12. REMOVE CROSS SHAFT
(a) Remove the clip and disconnect the No.2 gear shifting
rod.
(b) Remove the nut, washer, 4 bolts and the cross shaft.
Torque:
A (Transmission side): 13 N·m (130 kgf·cm, 9 ft·lbf)
B (Frame side): 28 N·m (290 kgf·cm, 21 ft·lbf)
C (Nut): 13 N·m (130 kgf·cm, 9 ft·lbf)
13. REMOVE OIL COOLER PIPE
(a) Remove the bolts and 3 clamps.
(b) Disconnect the 2 oil cooler pipes.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine AT0953
SST
AT02G−06
AT3306
Free Lock Hold
Turn
D00843
AT−38
− AUTOMATIC TRANSMISSIONTORQUE CONVERTER CLUTCH AND DRIVE PLATE
1379 Author: Date:
1996 TOYOTA T100 (RM449U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE−WAY CLUTCH
(a) Install SST in the inner race of one−way clutch.
SST 09350−30020 (09351−32010)
(b) Install SST so that it fits in the notch of the converter hub
and outer race of the one−way clutch.
SST 09350−30020 (09351−32020)
(c) With the torque converter clutch standing on its side,
check that the clutch locks when turned counterclock-
wise, and rotates freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch.
(d) Replace the converter if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If runout is not within the specification or if the ring gear is dam-
aged, replace the drive plate.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)