TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine TR021−02
Z19022
A/T:
M/T:High and Low Clutch Sleeve
High and Low Clutch Hub
 Key Retainer High and Low Clutch Hub
High and Low Hub Sleeve
Snap RingShifting Key Spring Snap Ring
Ball
Bearing
Spacer Rear Output Shaft
Shifting Key Spring
Front Drive Clutch Sleeve
Drive SprocketNeedle Roller Bearing
Shifting Key
Synchronizer Ring
 Non−reusable partShifting Key
− TRANSFERREAR OUTPUT SHAFT
TR−23
1403 Author: Date:
1996 TOYOTA T100 (RM449U)
REAR OUTPUT SHAFT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR0D3−01
TF0516
TF0517
TF0549
TF0518
SST
TF0620
TR−24
− TRANSFERREAR OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust clear-
ance.
Standard clearance:
0.10 − 0.25 mm (0.0039 − 0.0098 in.)
Maximum clearance: 0.25 mm (0.0098 in.)
If the clearance exceeds the maximum, replace the drive
sprocket.
2. M/T:
REMOVE HIGH AND LOW HUB SLEEVE
ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the hub sleeve and 3 shifting keys.
(c) Using a press, remove the clutch hub, 2 key springs and
key retainer.
3. A/T:
REMOVE HIGH AND LOW HUB SLEEVE
ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the hub sleeve.
(c) Using a press, remove the clutch hub.
4. REMOVE REAR BEARING, SPACER AND DRIVE
SPROCKET WITH FRONT DRIVE CLUTCH SLEEVE
ASSEMBLY
(a) Using SST and a press, remove the bearing.
SST 09950−00020
(b) Remove these parts:
Spacer and ball
Drive sprocket with front drive hub and hub sleeve
Needle roller bearing
Synchronizer ring

Downloaded from www.Manualslib.com manuals search engine TF0531
− TRANSFERREAR OUTPUT SHAFT
TR−25
1996 TOYOTA T100 (RM449U)
5. REMOVE 3 SHIFTING KEYS AND 2 KEY SPRINGS
FROM FRONT DRIVE HUB ASSEMBLY
Using a screwdriver, remove the 2 shifting key springs and 3
shifting keys.

Downloaded from www.Manualslib.com manuals search engine TR023−02
Q09962
AB
TF0522
TF0523
TF0524
TR−26
− TRANSFERREAR OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT REAR OUTPUT SHAFT
Using a micrometer, measure the outer diameter of the rear out-
put shaft journal surface.
Minimum diameter:
Part A: 27.98 mm (1.1016 in.)
Part B: 36.99 mm (1.4563 in.)
2. INSPECT DRIVE SPROCKET RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between
the sprocket and shaft with the needle roller bearing installed.
Standard clearance:
0.010 − 0.055 mm (0.0004 − 0.0022 in.)
Maximum clearance: 0.055 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the drive
sprocket, rear output shaft or needle roller bearing.
3. INSPECT FRONT DRIVE SHIFT FORK AND HUB
SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the front
drive shift fork and hub sleeve.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
4. INSPECT HIGH AND LOW SHIFT FORK AND HUB
SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the high
and low shift fork and hub sleeve.
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 TR024−02
TF0621
TF0624
Shifting
Key
Q02329
Slots
TF0532
SST
TF0516
− TRANSFERREAR OUTPUT SHAFT
TR−27
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. INSTALL FRONT DRIVE CLUTCH HUB AND HUB
SLEEVE
(a) Install the front drive hub sleeve onto the clutch hub.
HINT:
Make sure to install the hub sleeve in the correct direction.
(b) Install the 3 shifting keys and 2 springs.
NOTICE:
Install the key springs positioned so that their end gaps are
not in line.
2. INSTALL DRIVE SPROCKET WITH FRONT DRIVE
HUB SLEEVE ASSEMBLY, SPACER AND REAR
BEARING
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Install the synchronizer ring.
(c) Install the needle roller bearing in the drive sprocket.
(d) Install the drive sprocket with the front drive hub sleeve.
(e) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(f) Install the spacer to align it with the ball.
(g) Using SST and a press, install the rear bearing with the
outer race snap ring groove toward the rear.
SST 09316−60011 (09316−00011, 09316−00071)
3. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust clear-
ance.
Standard clearance:
0.10 − 0.25 mm (0.0039 − 0.0098 in.)

Downloaded from www.Manualslib.com manuals search engine TF0528
Shifting
Key
Shifting
Key SpringFront M/T:
TF0690
Front A/T:
TF0553
SST
TF0550
TF0550
TR−28
− TRANSFERREAR OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
4. M/T:
INSERT HIGH AND LOW CLUTCH HUB INTO HUB
SLEEVE
(a) Install the clutch hub and 3 shifting keys to the hub sleeve.
(b) Install the 2 shifting key springs under the 3 shifting keys.
NOTICE:
Install the key springs positioned so that their end gaps are
not in line.
5. A/T:
INSERT HIGH AND LOW CLUTCH HUB INTO HUB
SLEEVE
Install the clutch hub to the hub sleeve.
6. M/T:
INSTALL HIGH AND LOW HUB SLEEVE ASSEMBLY
(a) Using SST and a hammer, drive in a new key retainer.
SST 09316−60011 (09316−00011)
NOTICE:
Be careful not to deform or damage the key retainer.
(b) Using a press, install the high and low hub sleeve assem-
bly.
7. A/T:
INSTALL HIGH AND LOW HUB SLEEVE ASSEMBLY
Using a press, install the high and low hub sleeve assembly.

Downloaded from www.Manualslib.com manuals search engine TF0529
− TRANSFERREAR OUTPUT SHAFT
TR−29
1996 TOYOTA T100 (RM449U)
8. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install
it to the shaft.
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)
K2.00 − 2.05 (0.0787 − 0.0807)
L2.05 − 2.10 (0.0807 − 0.0827)

Downloaded from www.Manualslib.com manuals search engine TR025−02
TR−30
− TRANSFERINPUT SHAFT
1410 Author: Date:
1996 TOYOTA T100 (RM449U)
INPUT SHAFT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR026−02
TF0535
TF0552
TF0536
− TRANSFERINPUT SHAFT
TR−31
1996 TOYOTA T100 (RM449U)
INSPECTION
1. REMOVE SUN GEAR
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the sun gear from the input shaft.
2. INSPECT INPUT SHAFT
(a) Using a micrometer, measure the outer diameter of the in-
put shaft journal surface.
Minimum diameter: 47.59 mm (1.8736 in.)
(b) Using a dial indicator, measure the inside diameter of the
input shaft bushing.
Maximum inside diameter: 39.14 mm (1.5409 in.)
If the inside diameter exceeds the maximum, replace the input
shaft.
3. M/T:
INSPECT SYNCHRONIZER RING
(a) Turn the ring and push it in to check the braking action.
(b) Measure the clearance between the synchronizer ring
back and the input shaft spline end.
Standard clearance:
1.15 − 1.85 mm (0.0453 − 0.0728 in.)
Minimum clearance: 0.80 mm (0.0315 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.

Downloaded from www.Manualslib.com manuals search engine TF0537
TR−32
− TRANSFERINPUT SHAFT
1996 TOYOTA T100 (RM449U)
4. INSTALL SUN GEAR
(a) Install the sun gear to the input shaft.
HINT:
Make sure to install the sun gear in the correct direction.
(b) Using snap ring pliers, install the snap ring.