TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine AT028−02
D10995
Q06989
Q02711
Q02708
Spring
Casing
Cap
Control Select
ShaftControl Shaft
Support Sub−Assembly
Q02712
Casing Cap
− AUTOMATIC TRANSMISSIONSHIFT LOCK SYSTEM
AT−23
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. INSTALL CONTROL SHAFT SUPPORT
(a) Install the bushings, control shaft support sub−assembly
and plate washer.
(b) Using a snap ring expander, install the snap ring.
2. INSTALL SHIFT LEVER SUB−ASSEMBLY, CONTROL
SELECT SHAFT AND SPRING
(a) Insert the spring and control select shaft.
(b) Install the shift lever sub−assembly with the bolt and nut.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
3. INSTALL SHIFT LEVER PLATE SUB−ASSEMBLY
(a) Install the shift lever plate sub−assembly.
(b) Align the hole of the shift lever plate assembly and hole
of the control select shaft.
(c) Using a pin punch, tap in the slotted spring pin.
4. INSTALL PARKING LOCK CABLE ASSEMBLY
(a) Apply MP grease to the inside sliding surface of the con-
trol shaft support sub−assembly.
(b) Install the parking lock cable assembly to the control shaft
support sub−assembly, as shown.
(c) Tighten the casing cap.
Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Q02705
”R” direction
P position
L position
Q06988
AT−24
− AUTOMATIC TRANSMISSIONSHIFT LOCK SYSTEM
1996 TOYOTA T100 (RM449U)
5. CHECK PARKING LOCK CABLE OPERATION
(a) Push the parking lock cable to check that there is no
scraping noise and stopper knocking due to lack of
grease.
(b) Shift the shift lever in P position and check that the lever
is locked when you push the parking lock cable 7 mm
(0.28 in.).
(c) Check that the select lever is released when the parking
lock cable is free.
(d) Measure the freeplay of the tip of the control lever when
the control shaft is in play.
Freeplay: 6 mm (0.24 in.)
(e) Release the select lock and measure the freeplay of the
tip of the control lever when the shift lock plate and stop-
per lock in the shift direction.
Freeplay: 10 mm (0.39 in.)
(f) Shift the shift in P position and check that the shift lock
plate does not contact with the stopper when the control
shaft is rotated towards R position.
(g) With the stopper in operation, release shift lock and check
that shifting from P to R position is prevented when select-
ing a position.
(h) For each shift position from R to L position, check that the
ignition key plate turning from ACC position to LOCK posi-
tion is prevented.
6. INSTALL 3 CLAMPS
7. CHECK SHIFT LOCK SYSTEM

Downloaded from www.Manualslib.com manuals search engine AT029−01
Q02581
Q02704
Shift Lock
Release Link
Sliding Rod
Shift Lock
Plate Stopper
Q02703
Shift Lock Plate Stopper
Q02581
− AUTOMATIC TRANSMISSIONSHIFT LOCK SYSTEM
AT−25
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. TEMPORARILY INSTALL SHIFT LEVER ASSEMBLY
TO STEERING COLUMN ASSEMBLY
Install the shift lever assembly to the steering column assembly
with the 2 bolts.
2. CONNECT AND ADJUST INTER LOCK
(a) Put the control shaft in the P position.
(b) Turn the ignition key plate to the LOCK position.
(c) Slide the shift lock plate of the control shaft until it touch
the surface of the holder.
(d) Slide the sliding rod, then align the center of the shift lock
pate stopper’s hole and shift lock release link’s hole.
(e) Install the shift lock release link.
Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
(f) Tighten the screw.
Torque: 1.4 N·m (14 kgf·cm, 12 in.·lbf)
(g) Turn the ignition switch key plate in the ACC position.
(h) Set the control shaft in the D position.
(i) Measure the clearance of the stopper and shift lock plate.
Clearance: 1.0 ± 0.8 mm (0.039 ± 0.031 in.)
(j) When the control shaft is set in D position, check that the
ignition key plate does not turn to LOCK position.
(k) When the control lever is changed from the R position to
L position, check that the shift lock plate does not interfere
with stopper.
(l) Set the control shaft in the P position.
When the ignition key plate is turned from the LOCK posi-
tion to the ACC position, check that the stopper is un-
locked from the lock condition.
3. TORQUE SHIFT LEVER ASSEMBLY MOUNTING
BOLTS
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
4. INSTALL SHIFT LEVER ASSEMBLY WITH STEERING
COLUMN ASSEMBLY (See page SR−20)
5. CHECK AND ADJUST SHIFT LEVER POSITION
(See page DI−265)

Downloaded from www.Manualslib.com manuals search engine Q07584
3RZ−FE (A340E)
Front Exhaust Pipe
StarterOil Cooler Pipe
Plug for Hydraulic Test
Speedometer Cable
Bush
Cross Shaft
Rear Mounting
Insulator Rear End Plate O−Ring
Oil Filler Pipe No.2 Gear
Shifting Rod
 Non−reusable partPropeller Shaftx6
Rear Mounting Bracket
AT02A−02
AT−26
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340E)
1367 Author: Date:
1996 TOYOTA T100 (RM449U)
AUTOMATIC TRANSMISSION UNIT (A340E)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Q07585
5VZ−FE (A340E)
StarterOil Cooler Pipe
Plug for Hydraulic Cable
Speedometer Cable
Bush
No.2 Gear
Shifting Rod
No.1 Throttle Cable
Clamp Torque Converter
Clutch
Rear End Plate
Propeller Shaft
 Non−reusable partOil Filler Pipe
 O−Ring
Rear Mounting BracketCross Shaft x6 Throttle Cable
Rear Mounting Insulator
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340E)
AT−27
1368 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine AT02B−02
Q06797
Q06962
3RZ−FE AT−28
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340E)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE ATF LEVEL GAUGE
2. REMOVE ENGINE UNDER COVER
3. DISCONNECT THROTTLE CABLE
(a) Loosen the nut and disconnect the cable.
(b) Remove the throttle cable from the clamps.
4. 5VZ−FE:
REMOVE NO.1 THROTTLE CABLE CLAMP
Remove the 2 nuts and No.1 throttle cable clamp.
5. JACK UP VEHICLE
6. REMOVE OIL FILLER PIPE
Remove the bolt and oil filler pipe with the O−ring.
HINT:
At the time of reassembly, please refer to the following item.
Replace used O−ring with a new one.
7. REMOVE PROPELLER SHAFT (See page PR−3)
8. 3RZ−FE:
REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 bolts and retainer.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(c) Loosen the clamp bolt and disconnect the clamp from the
support bracket.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(d) Remove the 2 bolts and support bracket.
Torque: 71 N·m (730 kgf·cm, 53 ft·lbf)
(e) Remove the 3 nuts, front exhaust pipe and 3 gaskets.
Torque: 62 N·m (630 kgf·cm, 40 ft·lbf)
HINT:
At the time of reassembly, please refer to the following item.
Replace the used 3 gaskets with new ones.

Downloaded from www.Manualslib.com manuals search engine Q06796
5VZ−FE
Q06806
Z18883
A
B
C
Q06986
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340E)
AT−29
1996 TOYOTA T100 (RM449U)
9. 5VZ−FE:
REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 bolts and retainer.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(c) Remove the 3 bolts and support bracket.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
(d) Remove the 3 nuts, front exhaust pipe and 3 gaskets.
Torque: 62 N·m (630 kgf·cm, 40 ft·lbf)
HINT:
At the time of reassembly, please refer to the following item.
Replace the used 3 gaskets with new ones.
10. DISCONNECT SPEEDOMETER CABLE
(a) Loosen the serrated collar with pliers. Do not lose the felt
dust protector and washer.
(b) Disconnect the cable.
11. DISCONNECT NO.2 VEHICLE SPEED SENSOR CON-
NECTOR AND SOLENOID CONNECTOR
12. REMOVE CROSS SHAFT
(a) Remove the clip and disconnect the No.2 gear shifting
rod.
(b) Remove the nut, washer, 4 bolts and the cross shaft.
Torque:
A (Transmission side): 13 N·m (130 kgf·cm, 9 ft·lbf)
B (Frame side): 28 N·m (290 kgf·cm, 21 ft·lbf)
C (Nut): 13 N·m (130 kgf·cm, 9 ft·lbf)
13. REMOVE OIL COOLER PIPE
(a) Remove the bolts and 3 clamps.
(b) Disconnect the 2 oil cooler pipes.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Z15673
3RZ−FE
5VZ−FE
Q06810
3RZ−FE
Z14791
5VZ−FE
Q02647
AT−30
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340E)
1996 TOYOTA T100 (RM449U)
14. DISCONNECT ATF TEMPERATURE SENSOR
15. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
16. DISCONNECT STARTER WIRE
(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the starter connector.
17. REMOVE FRONT STABILIZER BAR
(See page SA−124)
18. 3RZ−FE:
REMOVE REAR END PLATE
Remove the 4 bolts, 2 nuts and rear end plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
19. 5VZ−FE:
REMOVE REAR END PLATE
Remove the 4 nuts, bolts and rear end plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
20. 3RZ−FE:
DISCONNECT REAR MOUNTING INSULATOR
Remove the 3 bolts and disconnect the rear mounting insulator.
Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)
21. 5VZ−FE:
DISCONNECT REAR MOUNTING INSULATOR
Remove the 4 bolts and disconnect the rear mounting insulator.
Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)
22. JACK UP TRANSMISSION
23. REMOVE TRANSMISSION WITH ENGINE
(a) Turn the crankshaft to gain access to each bolt, remove
the 6 bolts with holding the crankshaft pully bolt with a
wrench.
Torque: 41 N·m (420 kgf·cm, 30 ft·lbf)
(b) Disconnect the wire harness and connectors from the
transmission.
(c) Remove the transmission with the engine from the ve-
hicle. (See page 3RZ−FE EM−65, 5VZ−FE EM−65)

Downloaded from www.Manualslib.com manuals search engine Q06878
3RZ−FE
Q06879
5VZ−FE
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340E)
AT−31
1996 TOYOTA T100 (RM449U)
24. 3RZ−FE:
REMOVE TRANSMISSION FROM ENGINE
(a) Remove the 2 starter bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Remove the 3 transmission mounting bolts from the en-
gine.
Torque: 71 N·m (730 kgf·cm, 53 ft·lbf)
(c) Pull out the transmission toward the rear.
25. 5VZ−FE:
REMOVE TRANSMISSION FROM ENGINE
(a) Remove the 2 starter bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Remove the 6 transmission mounting bolts from the en-
gine.
Torque: 71 N·m (730 kgf·cm, 53 ft·lbf)
(c) Pull out the transmission toward the rear.

Downloaded from www.Manualslib.com manuals search engine D00842
AT02C−01
AT−32
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340E)
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. CHECK TORQUE CONVERTER CLUTCH INSTALLA-
TION
Using calipers and a straight edge, measure the distance from
the installed surface of the transmission housing to the installed
surface of the torque converter clutch.
Correct distance:
More than 31.75 mm (1.2500 in.) for 3RZ−FE
More than 17.95 mm (0.7067 in.) for 5VZ−FE
2. INSTALL TRANSMISSION
Installation is in the reverse order of removal (See page
AT−28).
HINT:
After installation, adjust the shift lever position (See page
DI−265).
Fill ATF and check the fluid level (See page DI−265).