TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine GM0060
WM0116
RM0023
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−31
1996 TOYOTA T100 (RM449U)
(d) Using a press, install the 3rd gear and hub sleeve No.2.
4. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A1.80 − 1.85 (0.0709 − 0.0728)
B1.85 − 1.90 (0.0728 − 0.0748)
C1.90 − 1.95 (0.0748 − 0.0768)
D1.95 − 2.00 (0.0768 − 0.0787)
E2.00 − 2.05 (0.0787 − 0.0807)
F2.05 − 2.10 (0.0807 − 0.0827)
G2.10 − 2.15 (0.0827 − 0.0846)
(b) Using a snap ring expander, install the snap ring.
5. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MT−26)
6. INSTALL 2ND GEAR AND REVERSE GEAR
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Align the projection of the synchronizer inner ring with the
slots of the clutch hub No.1.
(d) Install the needle roller bearing in the 2nd gear.
(e) Using a press, install the 2nd gear assembly and reverse
gear assembly.

Downloaded from www.Manualslib.com manuals search engine Z03560
Z03563
Z03564
Z03565
2WD: 4WD:
SST
SST MT−32
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
7. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.30 − 2.35 (0.0906 − 0.0925)
B2.35 − 2.40 (0.0925 − 0.0945)
C2.40 − 2.45 (0.0945 − 0.0965)
D2.45 − 2.50 (0.0965 − 0.0984)
E2.50 − 2.55 (0.0984 − 0.1004)
F2.55 − 2.60 (0.1004 − 0.1024)
G2.60 − 2.65 (0.1024 − 0.1043)
(b) Using a screwdriver and hammer, install the snap ring.
8. INSTALL SPACER AND 1ST GEAR ASSEMBLY
(a) Install the spacer on the output shaft.
(b) Apply gear oil to the needle roller bearing.
(c) Assemble the 1st gear, synchronizer ring and needle roll-
er bearing.
(d) Install the assembly on the output shaft with the synchro-
nizer ring slots aligned with the shifting keys.
9. INSTALL STRAIGHT PIN AND 1ST GEAR THRUST
WASHER
Install the 1st gear thrust washer onto the output shaft with the
straight pin aligned with the 1st gear thrust washer.
10. INSTALL OUTPUT SHAFT CENTER BEARING
(a) 2WD:
Using SST and a hammer, drive in the bearing with the
outer race snap ring groove toward the rear.
SST 09309−35010
(b) 4WD:
Using SST and a hammer, drive in the bearing with the
outer race snap ring groove toward the rear.
SST 09316−60011 (09316−00011, 09316−00071)

Downloaded from www.Manualslib.com manuals search engine Z03568
SST
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−33
1996 TOYOTA T100 (RM449U)
11. INSPECT 1ST GEAR THRUST CLEARANCE
(See page MT−26)
12. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MT−26)
13. INSTALL 5TH GEAR
Using SST and a press, install the 5th gear.
SST 09316−60011 (09316−00031)

Downloaded from www.Manualslib.com manuals search engine MT050−01
Z15462
Snap RingCounter Gear
Reverse Idler Gear Shaft
 Counter Gear Front Bearing
Reverse Idler GearGear Spline Piece No.5
Synchronizer Cone Ring
Hub Sleeve No.3
Counter 5th Gear
Needle Roller Bearing
Straight Pin
Thrust Washer
Counter Gear Rear Bearing
 Non−reusable partReverse Synchronizer RingShifting Key Shifting Key Spring5th Synchronizer Ring Reverse Synchronizer Pull RingSnap Ring MT−34
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1289 Author: Date:
1996 TOYOTA T100 (RM449U)
COUNTER GEAR AND REVERSE IDLER GEAR
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine MT051−01
Q07459
Q06828
Q06829
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
MT−35
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
REMOVE HUB SLEEVE NO.3, SHIFTING KEY AND SPRING
FROM SYNCHRONIZER RING
(a) Remove the synchronizer ring assembly from the hub
sleeve No.3.
(b) Turn the reverse synchronizer pull ring.
(c) Remove the reverse synchronizer ring and 5th synchro-
nizer ring from the synchronizer pull ring and cone ring.
(d) Turn the reverse synchronizer pull ring, separate the pull
ring and cone ring.
(e) Push the shifting key and spring, and remove the 3 shift-
ing keys and springs to the reverse synchronizer ring.

Downloaded from www.Manualslib.com manuals search engine MT052−01
Z03569
Q06689
Q06831
Q06832
MT−36
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Install the spacer, counter 5th gear and needle roller bear-
ings.
(b) Using a dial indicator, measure the counter 5th gear radial
clearance.
Standard clearance:
0.015 − 0.068 mm (0.0006 − 0.0027 in.)
Maximum clearance:
0.160 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the gear bear-
ing or shaft.
2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter
gear journal.
Minimum diameter: 27.860 mm (1.0968 in.)
If the outer diameter is less than the minimum, replace the
counter gear.
3. INSPECT 5TH SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer pull ring, cone ring and outer ring
to the gear spline piece No.5.
(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.

Downloaded from www.Manualslib.com manuals search engine WM0066
Q01803
Q06775
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
MT−37
1996 TOYOTA T100 (RM449U)
4. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
5. INSPECT REVERSE IDLER GEAR RADIAL CLEAR-
ANCE
Using a dial indicator, measure the reverse idler gear radial
clearance.
Standard clearance:
0.040 − 0.082 mm (0.0016 − 0.0032 in.)
Maximum clearance:
0.130 mm (0.0051 in.)
If the clearance exceeds the maximum, replace the reverse
idler gear or reverse idler gear shaft.
6. INSPECT REVERSE IDLER GEAR AND SHIFT ARM
CLEARANCE
Using a feeler gauge, measure the clearance between the re-
verse idler gear and shift arm.
Standard clearance:
0.05 − 0.35 mm (0.0020 − 0.0138 in.)
Maximum clearance:
0.50 mm (0.0197 in.)
If the clearance exceeds the maximum, replace the shift arm or
reverse idler gear.

Downloaded from www.Manualslib.com manuals search engine MT053−01
Z03575
SST
RM0013
Socket Wrench
Z03576
MT−38
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE COUNTER GEAR FRONT
BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the bearing.
SST 09950−00020
(c) Replace the side race.
(d) Using a socket wrench and press, install a new bearing
and side race.
(e) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.00 − 2.05 (0.0787 − 0.0807)
B2.05 − 2.10 (0.0807 − 0.0827)
C2.10 − 2.15 (0.0827 − 0.0846)
D2.15 − 2.20 (0.0846 − 0.0866)
E2.20 − 2.25 (0.0866 − 0.0886)
F2.25 − 2.30 (0.0886 − 0.0906)
(f) Using a snap ring expander, install the snap ring.

Downloaded from www.Manualslib.com manuals search engine MT054−01
Q06830
Q06828
Q07460
Q06819
Front
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
MT−39
1996 TOYOTA T100 (RM449U)
REASSEMBLY
INSTALL SYNCHRONIZER RING ASSEMBLY TO HUB
SLEEVE NO.3
(a) Put the key spring to the hole of the shifting key.
(b) Push the 3 shifting keys with the 3 key springs to the re-
verse synchronizer ring.
(c) Install the synchronizer cone ring to the reverse synchro-
nizer pull ring and turn the pull ring.
(d) Install the 5th synchronizer ring.
(e) Install the reverse synchronizer ring.
(f) Turn the reverse synchronizer pull ring.
(g) While pushing the 3 shifting keys, install the synchronizer
ring assembly to the hub sleeve No.3.

Downloaded from www.Manualslib.com manuals search engine MT055−01
RM0322 Non−reusable partFront Bearing Retainer Oil Seal MT−40
− MANUAL TRANSMISSION (R150, R150F)FRONT BEARING RETAINER OIL SEAL
1295 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BEARING RETAINER OIL SEAL
COMPONENTS