TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine AT022−06
OR0004
SST
OR0005
SST
− AUTOMATIC TRANSMISSIONEXTENSION HOUSING OIL SEAL (A340E)
AT−3
1344 Author: Date:
1996 TOYOTA T100 (RM449U)
EXTENSION HOUSING OIL SEAL
(A340E)
ON−VEHICLE REPAIR
1. REMOVE PROPELLER SHAFT (See page PR−3)
2. REMOVE REAR OIL SEAL
NOTICE:
Clean the extension housing before removing the oil seal.
Using SST, remove the oil seal.
SST 09308−10010
3. INSTALL NEW OIL SEAL
(a) Using SST and a hammer, carefully drive the oil seal in as
far as it will go.
SST 09325−40010
(b) Coat the lip of a new oil seal with MP grease.
4. INSTALL PROPELLER SHAFT (See page PR−9)
5. CHECK FLUID LEVEL (See page DI−265)

Downloaded from www.Manualslib.com manuals search engine AT023−02
Q06961
3RZ−FE
Z14780
5VZ−FE
Q06981
AT−4
− AUTOMATIC TRANSMISSIONSENSOR ROTOR (A340E)
1345 Author: Date:
1996 TOYOTA T100 (RM449U)
SENSOR ROTOR (A340E)
ON−VEHICLE REPAIR
1. REMOVE PROPELLER SHAFT (See page PR−3)
2. DISCONNECT SPEEDOMETER CABLE AND RE-
MOVE SPEEDOMETER DRIVEN GEAR
(See page AT−8)
3. REMOVE NO.2 VEHICLE SPEED SENSOR
(See page AT−10)
4. JACK UP TRANSMISSION SLIGHTLY
Securely support the transmission on a transmission jack. Lift
the transmission slightly from the crossmember.
5. 3RZ−FE:
REMOVE REAR MOUNTING BRACKET FROM REAR
SUPPORT MEMBER
Remove the 7 bolts from the rear mounting bracket.
6. 5VZ−FE:
REMOVE REAR MOUNTING BRACKET FROM REAR
SUPPORT MEMBER
Remove the 8 bolts from the rear mounting bracket.
7. REMOVE REAR MOUNTING INSULATOR FROM
EXTENSION HOUSING
Remove the 4 bolts and the engine rear mounting insulator from
the extension housing.

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Q00627
Q00626
3RZ−FE
Q07626
5VZ−FE
Q00626
3RZ−FE
− AUTOMATIC TRANSMISSIONSENSOR ROTOR (A340E)
AT−5
1346 Author: Date:
1996 TOYOTA T100 (RM449U)
8. REMOVE EXTENSION HOUSING AND GASKET
Remove the 6 bolts. If necessary, tap the extension housing
with a plastic hammer or a block of wood to loosen it.
9. REMOVE SPEEDOMETER DRIVE GEAR AND BALL
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the speedometer drive gear and ball.
10. 3RZ−FE:
REMOVE SENSOR ROTOR
(a) Remove the sensor rotor and key.
(b) Using snap ring pliers, remove the snap ring.
11. 5VZ−VE:
REMOVE SENSOR ROTOR
(a) Using a hammer handle, remove the sensor rotor from the
output shaft.
(b) Remove the lock ball.
12. 3RZ−FE:
INSTALL SENSOR ROTOR
(a) using snap ring pliers, install the snap ring.
(b) Install the key and sensor rotor.

Downloaded from www.Manualslib.com manuals search engine D00779
5VZ−FE
D00780
AT4357
Q06981
AT−6
− AUTOMATIC TRANSMISSIONSENSOR ROTOR (A340E)
1347 Author: Date:
1996 TOYOTA T100 (RM449U)
13. 5VZ−FE:
INSTALL SENSOR ROTOR
Install the lock ball and sensor rotor.
14. INSTALL SPEEDOMETER DRIVE GEAR AND BALL
(a) Install the speedometer drive gear and ball.
(b) Using a snap ring expander, install the snap ring.
15. INSTALL EXTENSION HOUSING AND GASKET
(a) Apply sealant or equivalent to the 6 bolts.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Install the extension housing with a new gasket to the
case.
(c) Install the 6 bolts.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
16. INSTALL REAR MOUNTING INSULATOR TO EXTEN-
SION HOUSING
Install the engine rear mounting insulator with the 4 bolts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Q06961
3RZ−FE
Z14780
5VZ−FE
− AUTOMATIC TRANSMISSIONSENSOR ROTOR (A340E)
AT−7
1348 Author: Date:
1996 TOYOTA T100 (RM449U)
17. 3RZ−FE:
INSTALL REAR MOUNTING BRACKET TO REAR SUP-
PORT MEMBER
Install the 7 bolts to the rear mounting bracket.
Torque:
Rear mounting side: 18 N·m (185 kgf·cm, 13 ft·lbf)
Frame side: 58 N·m (590 kgf·cm, 42 ft·lbf)
18. 5VZ−FE:
INSTALL REAR MOUNTING BRACKET TO REAR SUP-
PORT MEMBER
Install the 8 bolts from the rear mounting bracket.
Torque:
Rear mounting side: 18 N·m (185 kgf·cm, 13 ft·lbf)
Frame side: 58 N·m (590 kgf·cm, 42 ft·lbf)
19. INSTALL NO.2 VEHICLE SPEED SENSOR
(See page AT−10)
20. INSTALL SPEEDOMETER DRIVEN GEAR AND CON-
NECT SPEEDOMETER CABLE (See page AT−8)
21. INSTALL PROPELLER SHAFT (See page PR−9)

Downloaded from www.Manualslib.com manuals search engine Q04730
AT01W−02
Q06873
Z15613
A340E
SST
SST
A340F
Q07623
A340ESST
SST A340F
AT−8
− AUTOMATIC TRANSMISSIONSPEEDOMETER DRIVEN GEAR
1349 Author: Date:
1996 TOYOTA T100 (RM449U)
SPEEDOMETER DRIVEN GEAR
ON−VEHICLE REPAIR
1. DISCONNECT SPEEDOMETER CABLE AND RE-
MOVE SPEEDOMETER DRIVEN GEAR
(a) Loosen the serrated collar with pliers. Do not lose the felt
dust protector and washer.
(b) Disconnect the speedometer cable.
(c) Remove the bolt and locking plate. Pry out the speedom-
eter driven gear assembly.
(d) Remove the O−ring from the speedometer drive gear as-
sembly.
(e) Remove the clip and speedometer driven gear from the
speedometer driven gear sleeve.
2. REMOVE SPEEDOMETER DRIVEN GEAR OIL SEAL
Using SST, remove the oil seal.
SST 09921−00010
3. INSTALL SPEEDOMETER DRIVEN GEAR OIL SEAL
Using SST, install a new oil seal.
SST 09201−10000 (09201−01080)
Drive in depth: 20 mm (0.79 in.)
4. INSTALL SPEEDOMETER DRIVEN GEAR AND CON-
NECT SPEEDOMETER CABLE
(a) Install the clip and speedometer driven gear to the
speedometer driven gear sleeve.
(b) Install a new O−ring to the speedometer driven gear as-
sembly.
(c) Install the speedometer driven gear.
(d) Install the locking plate with the bolt.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(e) Connect the speedometer cable.

Downloaded from www.Manualslib.com manuals search engine Q04730
− AUTOMATIC TRANSMISSIONSPEEDOMETER DRIVEN GEAR
AT−9
1350 Author: Date:
1996 TOYOTA T100 (RM449U)
(f) Tighten the serrated collar with pliers.

Downloaded from www.Manualslib.com manuals search engine AT01X−01
Z14781
A340E
Z14782
A340F AT−10
− AUTOMATIC TRANSMISSIONVEHICLE SPEED SENSOR
1351 Author: Date:
1996 TOYOTA T100 (RM449U)
VEHICLE SPEED SENSOR
ON−VEHICLE REPAIR
1. DISCONNECT NO.2 VEHICLE SPEED SENSOR CON-
NECTOR
2. REMOVE NO.2 VEHICLE SPEED SENSOR
(a) A340E:
Remove the bolt and No.2 vehicle speed sensor.
(b) A340F:
Remove the bolt and No.2 vehicle speed sensor.
(c) Remove the O−ring from it.
3. INSTALL NO.2 VEHICLE SPEED SENSOR
(a) Cost a new O−ring with ATF and install it to the vehicle
speed sensor.
(b) Install the speed sensor and torque the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
4. CONNECT NO.2 VEHICLE SPEED SENSOR CONNEC-
TOR

Downloaded from www.Manualslib.com manuals search engine Q07624
AT01Y−01
− AUTOMATIC TRANSMISSIONPARK/NEUTRAL POSITION (PNP) SWITCH
AT−11
1352 Author: Date:
1996 TOYOTA T100 (RM449U)
PARK/NEUTRAL POSITION (PNP)
SWITCH
ON−VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPES
(See page A340E AT−28, A340F AT−34)
2. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Disconnect the connector.
(b) Pry off the lock washer and remove the nut.
(c) Remove the bolt and park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
(a) Install the park/neutral position switch and bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Install a new lock plate and the nut.
Torque: 3.9 N·m (40 kgf·cm, 35 in.·lbf)
(c) Bend claws on the lock plate to fix the nut.
(d) Connect the connector.
(e) Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.
If not as stated above, carry out the adjustment procedure.
(See page DI−265)
4. CONNECT OIL COOLER PIPES
(See page A340E AT−28, A340F AT−34)
5. TEST DRIVE VEHICLE

Downloaded from www.Manualslib.com manuals search engine AT0ZJ−01
Q07625
AT3168SST
AT0103
AT−12
− AUTOMATIC TRANSMISSIONVALVE BODY ASSEMBLY
1353 Author: Date:
1996 TOYOTA T100 (RM449U)
VALVE BODY ASSEMBLY
ON−VEHICLE REPAIR
CAUTION:
When working with FIPG material, you must observe the
followings.
Using a razor blade and a gasket scraper, remove all
oil FIPG material from the gasket surfaces.
Remove all loose material to thoroughly clean all
components.
Clean both sealing surfaces with a non−residue sol-
vent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead
along the sealing surface.
Parts must be assembled within 10 minutes of ap-
plication. Otherwise, the FIPG material must be re-
moved and reapplied.
1. REMOVE DRAIN PLUG AND DRAIN ATF
Torque: 20 N·m (205 kgf·cm, 15 ft·lbf)
2. REMOVE OIL PAN
NOTICE:
Some fluid will remain in the oil pan.
(a) Remove the 19 bolts.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
(b) Install the blade of SST between the transmission case
and oil pan, cut off applied sealer, and remove the oil pan.
SST 09032−00100
NOTICE:
When removing the oil pan, be careful not to damage the oil
pan flange.
3. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect steel particles.
Carefully look at the foreign matter and particles in the pan and
on the magnets to anticipate the type of wear you will find in the
transmission.
Steel (magnetic)......bearing, gear and clutch plate wear
Brass (non−magnetic) ...... bushing wear