TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine MT04Q−04
D10950
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−11
1266 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION ASSEMBLY
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Z15461
Output Shaft Assembly
Speedometer Drive Gear
Snap Ring Ball Bearing
Spacer
 Bearing Input Shaft
Synchronizer Ring
Rear Bearing Retainer
Gear Spline Piece No.5
Synchronizer Cone Ring
Hub Sleeve No.3 Reverse Idler Gear
Shifting Key SpringShaft
BallShifting Key
Counter 5th Gear
Reverse Synchronizer
Pull Ring
5th Synchronizer Ring
Reverse Synchronizer Ring Thrust Washer
Counter Gear Rear Bearing
Shift Fork Shaft No.2Needle Roller Bearing
Straight Pin Intermediate Plate
Counter Gear
 Front Bearing
Interlock Pin
Straight Pin
Shift Fork Shaft No.1
Slotted Spring Pin
Shift Fork No.3
2WD: 2WD:
Shift Fork No.1 Reverse Idler GearMagnet
Shift Fork Shaft No.3Shift Lever Housing
Shift and Select Lever
Shift Lever Housing
Shift and Select Lever4WD:
 Reverse Shift Arm Bracket
Reverse Shift Arm
E−Ring Reverse Shift Fork Shift Fork Shaft
No.4
 Non−reusable part
 Precoated part Bearing
Snap Ring
Snap Ring Snap RingSnap Ring
Snap Ring
Snap Ring
Snap Ring
 
Spring
Shift Fork No.2


Interlock Pin Snap Ring
Interlock Pin Snap Ring
Snap Ring
MT−12
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1267 Author: Date:
1996 TOYOTA T100 (RM449U)

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Q06902
FIPG
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−13
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE BACK−UP LIGHT SWITCH
Torque: 44 N·m (450 kgf·cm, 32 ft·lbf)
2. 2WD:
REMOVE SPEEDOMETER DRIVEN GEAR
Remove the driven gear lock plate set bolt and driven gear.
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
3. REMOVE CLUTCH HOUSING FROM TRANSMISSION
CASE
Remove the 9 bolts and clutch housing from the transmission
case.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
4. REMOVE CONTROL SHIFT LEVER RETAINER
(a) Remove the 6 (2WD) or 4 (4WD) bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the retainer and gasket (2WD) or oil deflector
(4WD).
5. REMOVE 2 RESTRICT PINS
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
6. 2WD:
REMOVE EXTENSION HOUSING
(a) Remove the shift lever housing set bolt.
Torque: 38 N·m (390 kgf·cm, 28 ft·lbf)
(b) Remove the 10 bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(c) Using a plastic hammer, tap the extension housing, re-
move the shift lever housing and shift and select lever.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or
equivalent

Downloaded from www.Manualslib.com manuals search engine Q06901
FIPG
Q06900
FIPG
x8
Q06903
FIPG
MT−14
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
7. 4WD:
REMOVE TRANSFER ADAPTOR
(a) Remove the shift lever housing set bolt.
Torque: 38 N·m (390 kgf·cm, 28 ft·lbf)
(b) Remove the 10 bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(c) Using a plastic hammer, tap the transfer adaptor, remove
the shift lever housing and the shift and select lever.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or
equivalent
8. REMOVE FRONT BEARING RETAINER
(a) Remove the 8 bolts.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 17 N·m (170 kgf·cm, 12 ft·lbf)
(b) Using a plastic hammer, tap the front bearing retainer.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or
equivalent
9. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
10. SEPARATE INTERMEDIATE PLATE FROM TRANS-
MISSION CASE
(a) Using a brass bar and hammer, carefully tap the transmis-
sion case.
(b) Remove the transmission case from the intermediate
plate.
HINT:
At the time of reassembly, please refer to the following item.
Align the each bearing outer race, each fork shaft end and re-
verse idler gear shaft end with the case installation holes.

Downloaded from www.Manualslib.com manuals search engine Q06785
Q06905
Q06764
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−15
1996 TOYOTA T100 (RM449U)
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or
equivalent
11. REMOVE MAGNET FROM INTERMEDIATE PLATE
12. MOUNT INTERMEDIATE PLATE IN VISE
(a) Use the 2 clutch housing bolts, plate washers and suit-
able nuts, as shown.
HINT:
Increase or decrease plate washers so that the bolt tip does not
protrude from the nut.
(b) Mount the intermediate plate in a vise.
13. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench, remove the 4 plugs.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(b) Using a magnetic finger, remove the 3 springs and balls.
14. REMOVE SHIFT FORK SET BOLT
Remove the 2 bolts from the shift forks No.1 and No.2.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
15. REMOVE SLOTTED SPRING PIN
Using a pin punch and hammer, drive out the pin from the shift
fork No.3.
16. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the 4 snap rings
from each shift fork shaft.

Downloaded from www.Manualslib.com manuals search engine Q06766
Q06763
Q06768
Q06904
Q06771
MT−16
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
17. REMOVE SHIFT FORK SHAFT NO.2 AND SHIFT FORK
NO.2
(a) Pull out the shift fork shaft No.2 from the shift forks No.1,
No.2 and intermediate plate.
(b) Remove the shift fork No.2 from the groove of hub sleeve
No.2.
(c) Using a magnetic finger, remove the interlock pin from the
intermediate plate.
18. REMOVE SHIFT FORK SHAFT NO.1 AND SHIFT FORK
NO.1
(a) Pull out the shift fork shaft No.1 with the straight pin from
the shift fork No.1 and intermediate plate.
(b) Remove the shift fork No.1 from the groove of reverse
gear.
(c) Using a magnetic finger, remove the interlock pin from the
intermediate plate.
19. REMOVE SHIFT FORK SHAFT NO.3 AND SHIFT FORK
NO.3
(a) Pull out the shift fork shaft No.3 from the shift fork No.3,
reverse shift fork and intermediate plate.
(b) Remove the shift fork No.3 from the groove of hub sleeve
No.3.
(c) Using a magnetic finger, remove the interlock pin from the
intermediate plate.
20. REMOVE SHIFT FORK SHAFT NO.4
(a) Using a magnetic finger, remove the ball.
(b) Pull out the shift fork shaft No.4 from the reverse shift fork
and intermediate plate.
NOTICE:
Take care of the ball in the reverse shift fork. It will spring
out when you pull out the shift fork shaft No.4.
(c) Using a magnetic finger, remove the spring from the re-
verse shift fork.
21. REMOVE REVERSE SHIFT FORK AND ARM
(a) Remove the reverse shift fork and arm.
HINT:
At the time of reassembly, please refer to the following item.
Align the reverse shift arm to the pivot of the reverse shift arm
bracket.
(b) Using a screwdriver, remove the E−ring.
(c) Separate the reverse shift fork and arm.

Downloaded from www.Manualslib.com manuals search engine RM0063
RM0072
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−17
1996 TOYOTA T100 (RM449U)
22. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and reverse shift arm bracket.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
23. 2WD:
REMOVE SPEEDOMETER DRIVE GEAR
(a) Using 2 screwdrivers and a hammer, tap out the rear snap
ring, and remove the drive gear and ball.
(b) Using 2 screwdrivers and a hammer, tap out the front
snap ring, and remove the drive gear.
24. REMOVE OUTPUT SHAFT REAR BEARING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.65 − 2.70 (0.1043 − 0.1063)
B2.70 − 2.75 (0.1063 − 0.1083)
C2.75 − 2.80 (0.1083 − 0.1102)
D2.80 − 2.85 (0.1102 − 0.1122)
E2.85 − 2.90 (0.1122 − 0.1142)
F2.90 − 2.95 (0.1142 − 0.1161)
G2.95 − 3.00 (0.1161 − 0.1181)
H3.00 − 3.05 (0.1181 − 0.1201)
J3.05 − 3.10 (0.1201 − 0.1220)
K3.10 − 3.15 (0.1220 − 0.1240)
L3.15 − 3.20 (0.1240 − 0.1260)
M3.20 − 3.25 (0.1260 − 0.1280)
N3.25 − 3.30 (0.1280 − 0.1299)
P3.30 − 3.35 (0.1299 − 0.1319)
Q3.35 − 3.40 (0.1319 − 0.1339)
R3.40 − 3.45 (0.1339 − 0.1358)
S3.45 − 3.50 (0.1358 − 0.1378)

Downloaded from www.Manualslib.com manuals search engine Z14821
SST 4WD:
Z14820
SST
2WD:
RM0070
SST 2WD:
RM0071
SST 4WD:
Q06786
MT−18
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
(b) Using SST, remove the rear bearing.
SST 09950−40010
HINT:
At the time of reassembly, please refer to the following items.
2WD:
Using SST and a hammer, drive in a new bearing.
SST 09309−35010
4WD:
Using SST and a hammer, drive in a new bearing.
SST 09316−60011 (09316−00011, 09316−00071)
25. REMOVE SPACER
26. INSPECT COUNTER 5TH GEAR THRUST CLEAR-
ANCE
Using a feeler gauge, measure the counter 5th gear thrust
clearance.
Standard clearance:
0.10 − 0.35 mm (0.0039 − 0.0138 in.)
Maximum clearance:
0.40 mm (0.0157 in.)

Downloaded from www.Manualslib.com manuals search engine Q06688
Q06605
SST
RM0024
SST
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−19
1996 TOYOTA T100 (RM449U)
27. REMOVE GEAR SPLINE PIECE NO.5, SYNCHRONIZ-
ER RING, NEEDLE ROLLER BEARING AND COUNT-
ER 5TH GEAR WITH HUB SLEEVE NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.80 − 2.85 (0.1102 − 0.1122)
B2.85 − 2.90 (0.1122 − 0.1142)
C2.90 − 2.95 (0.1142 − 0.1161)
D2.95 − 3.00 (0.1161 − 0.1181)
E3.00 − 3.05 (0.1181 − 0.1201)
F3.05 − 3.10 (0.1201 − 0.1220)
G3.10 − 3.15 (0.1220 − 0.1240)
(b) Using SST, remove the gear spline piece No.5.
SST 09950−50010
(c) Remove the counter 5th gear with the hub sleeve No.3.
HINT:
At the time of reassembly, please refer to the following items.
Using SST and a hammer, drive in the gear spline piece
No.5 with the synchronizer ring slots aligned with the shift-
ing keys.
SST 09316−60011 (09316−00011)
When installing the gear spline piece No.5, support the
counter gear in front with a 1.4 − 2.3 kg (3 − 5 lb) hammer
or equivalent.
28. REMOVE THRUST WASHER AND BALL FROM
COUNTER GEAR
29. REMOVE REAR BEARING RETAINER
Remove the 4 bolts and rear bearing retainer.
HINT:
At the time of reassembly, please refer to the following item.
Align the rear bearing retainer to the reverse idler gear shaft
groove.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Z03540
RM0010
Q07393
SST
Q07552
SST
SST
25 mm MT−20
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
30. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft toward the rear.
HINT:
At the time of the reassembly, please refer to the following item.
Align the reverse shift arm to the reverse idler gear shaft.
31. REMOVE OUTPUT SHAFT CENTER BEARING SNAP
RING
Using a snap ring expander, remove the snap ring.
32. REMOVE OUTPUT SHAFT AND COUNTER GEAR
FROM INTERMEDIATE PLATE
(a) Remove the output shaft, counter gear and input shaft as
a unit from the intermediate plate by pulling on the counter
gear and tapping on the intermediate plate with a plastic
hammer.
(b) Remove the input shaft with the needle roller bearing from
the output shaft.
33. REMOVE COUNTER REAR BEARING FROM INTER-
MEDIATE PLATE
Using SST and a hammer, remove the counter rear bearing.
SST 09950−60010 (09951−00620), 09950−70010
(09951−07150)
34. 2WD:
IF NECESSARY, REPLACE SPEEDOMETER DRIVEN
GEAR OIL SEAL
(a) Using SST, remove the oil seal.
SST 09921−00010
(b) Coat the lip of oil seal with MP grease.
(c) Using SST, drive in a new oil seal.
SST 09201−10000 (09201−01080), 09950−70010
(09951−07150)
Drive in depth: 25 mm (0.98 in.)