TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine MT04I−02
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION SYSTEM
MT−1
1256 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION SYSTEM
PRECAUTION
When working with FIPG material, you must observe the following items.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.

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MT−2
− MANUAL TRANSMISSION (R150, R150F)TROUBLESHOOTING
1257 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
1. Oil (Level low) 2WD
4WD
2. Oil (Wrong) 2WD
4WD
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−4
MT−7
MT−4
MT−7
MT−11
MT−11
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MT−4
MT−7
MT−11
MT−11
MT−11
Hard to shift or will not shift
1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)MT−22
MT−25
MT−34
MT−25
MT−34
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−11
MT−11
MT−11
MT−11

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D10947
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (2WD)
MT−3
1258 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION UNIT (2WD)
COMPONENTS

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Down
ClothCounterclockwise
MT0ER−01
D10948
MT−4
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION WITH ENGINE (See page
EM−65)
2. REMOVE REAR END PLATE
Remove the 4 bolts, nuts and rear end plate.
Torque:37 N·m (380 kgf·cm, 27 ft·lbf)
3. REMOVE STARTER
Remove the 2 bolts and starter.
Torque:39 N·m (400 kgf·cm, 29 ft·lbf)
4. REMOVE TRANSMISSION FROM ENGINE
(a) Remove the 6 transmission mounting bolts from the en-
gine.
Torque:72 N·m (730 kgf·cm, 53 ft·lbf)
(b) Pull out the transmission toward the rear.
5. REMOVE ENGINE REAR MOUNTING
(a) Remove the 4 bolts and engine rear mounting.
Torque:25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Lower the front side of the transmission and remove it
from the front side of the vehicle.

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− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (2WD)
MT−5
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page MT−4).
HINT:
After installation, do the road test.

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D10949
MT−6
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
1261 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION UNIT (4WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine MT0501
Down
ClothCounterclockwise
MT04O−02
Q06817
Installation
Front
Select Return Spring
Tip of Shift Lever
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
MT−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION SHIFT LEVER
(a) Remove the 4 screws and front console box.
(b) Remove the 4 screws and shift lever boot retainer.
(c) Cover the shift lever cap with a cloth.
(d) Then, pressing down on the shift lever cap, rotate it coun-
terclockwise to remove.
(e) Pull out the shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of the shift lever.
2. REMOVE TRANSFER SHIFT LEVER
Using snap ring pliers, remove the snap ring and pull out the
shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of shift lever.
3. RAISE VEHICLE AND DRAIN TRANSMISSION OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 2.2 liters (2.3 US qts, 1.9 Imp. qts)
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE FRONT AND REAR PROPELLER SHAFTS
(See page PR−10)
5. DISCONNECT SPEEDOMETER CABLE
6. DISCONNECT BACK−UP LIGHT SWITCH AND 4WD
INDICATOR SWITCH CONNECTORS
7. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
Remove the 4 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Q06824
Q06823
Q06822
Q10111
MT−8
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
1996 TOYOTA T100 (RM449U)
8. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 nuts, gasket and oxygen sensor.
(b) Remove the 2 bolts, retainer and gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(c) Remove the 3 bolts and bracket.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
(d) Remove the 3 nuts, front exhaust pipe and 2 gaskets.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
9. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
10. RE MO V E STIFFE NE R PLATE (RH AND LH) AND
REAR END PLATE
Remove the 8 bolts, stiffener plate (RH and LH) and rear end
plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
11. REMOVE STABILIZER BAR (See page SA−126)
12. JACK UP TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.
13. REMOVE CROSSMEMBER
(a) Remove the 4 set bolts of the engine rear mounting.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Remove the 8 bolts and crossmember.
Torque: 95 N·m (970 kgf·cm, 70 ft·lbf)
14. REMOVE TRANSMISSION WITH TRANSFER
(a) Remove the 6 transmission mounting bolts from the en-
gine.
Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
(b) Disconnect the 3 wire clamps from the transmission.
(c) Pull out the transmission with the transfer down and to-
ward the rear.
15. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

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− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
MT−9
1996 TOYOTA T100 (RM449U)
16. REMOVE TRANSFER FROM TRANSMISSION
(a) Remove the transfer adaptor rear mounting bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) 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.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the adaptor oil seal and shift the 2 shift fork
shafts to the high − 4 position.

Downloaded from www.Manualslib.com manuals search engine MT04P−04
MT−10
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page MT−7).
HINT:
After installation, do the road test.