TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine CL02F−01
Q02475
CL−12
− CLUTCHCLUTCH RELEASE CYLINDER
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. PULL OUT BOOT WITH PUSH ROD
2. REMOVE PISTON
Using compressed air, remove the piston with the spring from
the cylinder.

Downloaded from www.Manualslib.com manuals search engine CL02G−01
Z07291
− CLUTCHCLUTCH RELEASE CYLINDER
CL−13
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSTALL PISTON WITH SPRING INTO CYLINDER
3. INSTALL BOOT WITH PUSH ROD TO CYLINDER

Downloaded from www.Manualslib.com manuals search engine CL02H−02
CL−14
− CLUTCHCLUTCH RELEASE CYLINDER
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page CL−11).
HINT:
After installation, bleed clutch system.

Downloaded from www.Manualslib.com manuals search engine CL02I−03
Q08025
Flywheel Pilot Bearing
Clutch Disc
Clutch Release Bearing
Clutch Release Fork
Clutch Cover
 Non−reusable partClutch Release
Fork Support Boot 3RZ−FE:Clip
Clutch Disc
− CLUTCHCLUTCH UNIT
CL−15
1250 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH UNIT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine CL02J−01
Q06639
Matchmarks
Q06637
CL−16
− CLUTCHCLUTCH UNIT
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION FROM ENGINE
W59: See page MT−3
R150 (2WD): MT−3
R150F (4WD): MT−6
2. REMOVE CLUTCH COVER AND DISC
(a) Place matchmarks on the flywheel and clutch cover.
(b) Loosen each set bolt one turn at a time until spring tension
is released.
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
3. REMOVE BOOT, RELEASE BEARING AND FORK
FROM TRANSMISSION
Remove the boot and release bearing together with the fork and
then separate them.

Downloaded from www.Manualslib.com manuals search engine CL02K−04
CL0239
CL0373
Q07250
Q02481
Q02482
SST
− CLUTCHCLUTCH UNIT
CL−17
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 in.)
If necessary, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 in.)
If necessary, replace the clutch disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 in.)
If necessary, replace the flywheel.
4. INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the rotation
direction.
If the bearing sticks or has much resistance, replace the pilot
bearing.
HINT:
The bearing is permanently lubricated and requires no clearing
or lubrication.
5. IF NECESSARY, REPLACE PILOT BEARING
(a) Using SST, remove the pilot bearing.
SST 09303−35011

Downloaded from www.Manualslib.com manuals search engine Q02483
SST
Z10062
B
A
N00414
CL−18
− CLUTCHCLUTCH UNIT
1996 TOYOTA T100 (RM449U)
(b) Using SST, install a new pilot bearing.
SST 09304−30012
HINT:
After assembling the pilot bearing to the hub, install sure that
it rotates smoothly.
6. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum
Depth A: 0.6 mm (0.024 in.)
Width B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If necessary, replace the release bearing.

Downloaded from www.Manualslib.com manuals search engine CL02L−01
Q06647
5VZ−FE 3RZ−FE
SST Flywheel
Side
Q06958
1,4
7
3
62,58 Matchmarks
Q06641
SST
Z00762
Q06642
− CLUTCHCLUTCH UNIT
CL−19
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them and the
clutch cover in position.
SST 09301−00110
(b) Align the matchmarks on the clutch cover and flywheel.
(c) Torque the 6 bolts on the clutch cover in the order shown.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non−alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333−00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to the these parts.
Release fork and hub contact point
Release fork and push rod contact point
Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887−01706 (100g).
4. INSTALL BOOT, RELEASE BEARING AND FORK TO
TRANSMISSION
Install the boot and bearing to the release fork, and then install
them to the transmission.

Downloaded from www.Manualslib.com manuals search engine CL−20
− CLUTCHCLUTCH UNIT
1996 TOYOTA T100 (RM449U)
5. INSTALL TRANSMISSION TO ENGINE
W59: See page MT−3
R150 (2WD): See page MT−3
R150F (4WD):See page MT−6

Downloaded from www.Manualslib.com manuals search engine MT – MANUAL TRANSMISSION (R150, R150F)

MANUAL TRANSMISSION SYSTEM MT-1
TROUBLESHOOTING MT-2
MANUAL TRANSMISSION UNIT (2WD) MT-3
MANUAL TRANSMISSION UNIT (4WD) MT-6
MANUAL TRANSMISSION ASSEMBLY MT-11
INPUT SHAFT MT-22
OUTPUT SHAFT MT-25
COUNTER GEAR AND REVERSE
IDLER GEAR MT-34
FRONT BEARING RETAINER OIL SEAL MT-40
EXTENSION HOUSING AND
TRANSFER ADAPTOR MT-42