TOYOTA T100 1996 Factory Service Manual

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TF0467
TF0468
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TF0471
− TRANSFERTRANSFER ASSEMBLY
TR−13
1996 TOYOTA T100 (RM449U)
17. M/T:
REMOVE SYNCHRONIZER RING FROM INPUT
SHAFT
HINT:
At the time of installation, please refer to the following items.
Apply gear oil to the synchronizer ring.
Align the synchronizer ring slots with the shifting keys,
and install it on the high and low clutch hub.
18. REMOVE SEPARATOR WITH OIL STRAINER
(a) Remove the 3 bolts and the separator with the oil strainer.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the O−ring from the oil strainer pipe.
HINT:
At the time of installation, please refer to the following item.
Coat a new O−ring with gear oil and install it to the oil strainer
pipe.
19. REMOVE OIL PUMP BODY ASSEMBLY
Remove the 3 bolts and the oil pump body assembly.
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
20. REMOVE OIL PUMP DRIVE GEAR
21. REMOVE PLANETARY GEAR ASSEMBLY WITH
INPUT SHAFT
(a) Using a snap ring expander, remove the snap ring.
(b) Pull out the planetary gear assembly with the input shaft.
HINT:
At the time of installation, please refer to the following item.
If necessary, heat the front case to about 70°C (158°F).

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TF0474
TR−14
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
22. REMOVE LOW GEAR SPLINE PIECE
(a) Using a screwdriver, remove the snap ring.
HINT:
At the time of installation, please refer to the following item.
Be sure the end gap of the snap ring is not aligned with cutout
portion of the planetary carrier.
(b) Remove the low gear spline piece.
23. REMOVE NEEDLE ROLLER BEARING FROM INPUT
SHAFT
HINT:
At the time of installation, apply gear oil to the needle roller bear-
ing.
24. REMOVE INPUT SHAFT STOPPER AND THRUST
BEARING
(a) Using a snap ring expander, remove the snap ring.
HINT:
At the time of installation, please refer to the following item.
Select a snap ring that will allow 0.05 − 0.15 mm (0.0020 −
0.0059 in.) axial play.
MarkThickness mm (in.)
A2.10 − 2.15 (0.0827 − 0.0846)
B2.15 − 2.20 (0.0846 − 0.0866)
C2.20 − 2.25 (0.0866 − 0.0886)
D2.25 − 2.30 (0.0886 − 0.0906)
E2.30 − 2.35 (0.0906 − 0.0925)
F2.35 − 2.40 (0.0925 − 0.0945)
G2.40 − 2.45 (0.0945 − 0.0965)
H2.45 − 2.50 (0.0965 − 0.0984)
J2.50 − 2.55 (0.0984 − 0.1004)
K2.55 − 2.60 (0.1004 − 0.1024)
L2.60 − 2.65 (0.1024 − 0.1043)
M2.65 − 2.70 (0.1043 − 0.1063)
N2.70 − 2.75 (0.1063 − 0.1083)
P2.75 − 2.80 (0.1083 − 0.1102)
Q2.80 − 2.85 (0.1102 − 0.1122)
R2.85 − 2.90 (0.1122 − 0.1142)
S2.90 − 2.95 (0.1142 − 0.1161)
T2.95 − 3.00 (0.1161 − 0.1181)
U3.00 − 3.05 (0.1181 − 0.1201)

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TF0507
− TRANSFERTRANSFER ASSEMBLY
TR−15
1996 TOYOTA T100 (RM449U)
(b) Remove the input gear stopper, thrust bearing, race and
the 2 pins.
HINT:
At the time of installation, apply gear oil to the thrust bearing and
race.
25. REMOVE INPUT SHAFT, THRUST BEARING AND
RACE
26. REMOVE PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring.
HINT:
At the time of installation, please refer to the following item.
Be sure the end gap of the snap ring is not aligned with the up-
per side of the case.
(b) Remove the plug, spring and pin.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the plug.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Remove the planetary ring gear.
HINT:
At the time of installation, make sure to install the ring gear in
the correct direction.

Downloaded from www.Manualslib.com manuals search engine TR01W−01
TR−16
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page TR−7).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before assembly.

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− TRANSFEROIL PUMP BODY
TR−17
1397 Author: Date:
1996 TOYOTA T100 (RM449U)
OIL PUMP BODY
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR0D0−01
TF0547
TF0485
TR−18
− TRANSFEROIL PUMP BODY
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. CHECK OIL PUMP OPERATION
Install the oil pump drive gear to the drive rotor and check that
the drive rotor turns smoothly.
2. REMOVE STRAIGHT SCREW PLUG, SPRING, BALL
AND SEAT
(a) Using a hexagon wrench, remove the straight screw plug.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the plug.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Using a magnetic finger remove the spring and ball.
(c) Using SST, pull out the seat.
SST 09921−00010
(d) Remove the O−ring from the seat.
HINT:
At the time of reassembly, please refer to the following items.
Install a new O−ing to the seat.
When installing the seat, push the seat until it touches the
bottom of the hole in the body.
3. REMOVE OIL PUMP PLATE
(a) Using a torx socket wrench (T30), unscrew the 3 torx
screws.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
(b) Remove the oil pump plate.
4. REMOVE DRIVE ROTOR AND DRIVEN ROTOR
HINT:
At the time of reassembly, apply gear oil to the both rotors.

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TF0486
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− TRANSFEROIL PUMP BODY
TR−19
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT DRIVEN ROTOR BODY CLEARANCE
(a) Push the driven rotor to one side of the body.
(b) Using a feeler gauge, measure the clearance.
Standard clearance:
0.10 − 0.16 mm (0.0039 − 0.0063 in.)
Maximum clearance: 0.16 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the drive rotor,
driven rotor or pump body.
2. INSPECT BOTH ROTORS TIP CLEARANCE
Using a feeler gauge, measure the clearance between both ro-
tor tips.
Standard clearance:
0.08 − 0.16 mm (0.0031 − 0.0063 in.)
Maximum clearance: 0.16 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the drive rotor,
driven rotor or pump body.
3. INSPECT BOTH ROTORS SIDE CLEARANCE
Using a steel straight edge and feeler gauge, measure the
clearance between the rotors and straight edge.
Standard clearance:
0.03 − 0.08 mm (0.0012 − 0.0031 in.)
Maximum clearance: 0.08 mm (0.0031 in.)
If the clearance exceeds the maximum, replace the drive rotor,
driven rotor or pump body.

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TR−20
− TRANSFEROIL PUMP BODY
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page TR−18).

Downloaded from www.Manualslib.com manuals search engine TR01Z−02
− TRANSFERDRIVEN SPROCKET
TR−21
1401 Author: Date:
1996 TOYOTA T100 (RM449U)
DRIVEN SPROCKET
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR020−02
TF0512
TF0513
Steel Bar
SST
TF0514
TF0515
TR−22
− TRANSFERDRIVEN SPROCKET
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE FRONT BEARING
Using a press, remove the front bearing.
2. REMOVE REAR BEARING
Using SST, steel bar and a press, remove the rear bearing.
SST 09950−00020
3. INSTALL REAR BEARING
Using a press, install the rear bearing.
4. INSTALL FRONT BEARING
Using a press, install the front bearing.
HINT:
Make sure to install the bearing in the correct direction.