TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine Q00863
Q00864
MT−26
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
(d) Using a micrometer, measure the outer diameter of the in-
ner race.
Minimum diameter: 42.975 mm (1.6919 in.)
If the outer diameter is less than the minimum, replace the inner
race.
(e) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)
If the runout exceeds the maximum, replace the output shaft.

Downloaded from www.Manualslib.com manuals search engine MT03V−01
Q00888
Z02648
No.2 No.1
Front Front
Q00865
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−27
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 AND NO.2 CLUTCH HUBS INTO HUB
SLEEVE
(a) Install the 3 shifting key springs to the clutch hub.
(b) While pushing the shifting key spring with a screwdriver,
install the 3 shifting keys.
(c) While pushing the 3 shifting keys, install the clutch hub to
the hub sleeve, as shown.
2. INSTALL 3RD GEAR AND NO.2 CLUTCH HUB ON
OUTPUT SHAFT
(a) Apply gear oil to the shaft.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.

Downloaded from www.Manualslib.com manuals search engine WM0115
Q00887
Q00866
WM0119
MT−28
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
(c) Using a press, install the 3rd gear and No.2 clutch hub.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
C−11.75 − 1.80 (0.0689 − 0.0709)
D1.80 − 1.85 (0.0709 − 0.0728)
111.86 − 1.91 (0.0732 − 0.0752)
121.92 − 1.97 (0.0756 − 0.0776)
131.98 − 2.03 (0.0780 − 0.0799)
142.04 − 2.09 (0.0803 − 0.0823)
152.10 − 2.15 (0.0827 − 0.0846)
(b) Using a snap ring expander, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MT−21)
5. INSTALL 2ND GEAR AND NO.1 CLUTCH HUB
(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) Install the needle roller bearing in the 2nd gear.
(d) Using a press, install the 2nd gear and No.1 clutch hub.
6. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MT−21)

Downloaded from www.Manualslib.com manuals search engine Q00868
WM0122
SST
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−29
1996 TOYOTA T100 (RM449U)
7. INSTALL LOCKING BALL AND 1ST GEAR ASSEMBLY
(a) Install the locking ball in the shaft.
(b) Apply gear oil to the bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller
bearing and bearing inner race.
(d) Install the assembly on the output shaft with the synchro-
nizer ring slots aligned with the shifting keys and turn the
inner race to align it with the locking ball.
8. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a press, install the bearing on the output shaft
with the outer race snap ring groove toward the rear.
SST 09506−35010
HINT:
Hold the 1st gear inner race to prevent it from falling.
9. INSPECT 1ST GEAR THRUST CLEARANCE
(See page MT−21)

Downloaded from www.Manualslib.com manuals search engine MT03W−03
Z15652
Shaft Stopper
Reverse Idler Gear Shaft
Reverse Idler ShaftSnap Ring
Race
Counter Gear
Counter 5th Gear
Reverse Synchronizer
Pull Ring
Shifting Key Spring
No.3 Clutch Hub
Reverse Synchronizer Ring No.3 Hub Sleeve5th Synchronizer RingSynchronizer Cone BearingNeedle Roller Bearing Shifting Key
Spacer
Non−reusable part Snap RingSnap Ring Snap Ring
Bearing 
Bearing 
Spacer Snap Ring Race
Bearing  MT−30
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
1329 Author: Date:
1996 TOYOTA T100 (RM449U)
COUNTER GEAR AND REVERSE IDLER GEAR
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine MT03X−01
Q03887
Q04037
Q00873
Q04010
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
MT−31
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
REMOVE NO.3 HUB SLEEVE, SHIFTING KEY AND SPRING
FROM SYNCHRONIZER RING
(a) Remove the synchronizer ring assembly from the No.3
hub sleeve.
(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 and separate the
pull ring and cone ring.
(e) Remove the 3 shifting keys and key springs by carefully
levering up the shifting key spring with one screwdriver
and levering the shifting key away from the reverse syn-
chronizer ring with another screwdriver.

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 Q07367
SST
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
MT−35
1996 TOYOTA T100 (RM449U)
(c) Using SST, tap out the bearing outer race.
SST 09950−60010 (09951−00510), 09950−70010
(09951−07150)
HINT:
After the outer race has been installed, the transmission is reas-
sembled.