TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine TR027−02
TF0492
− TRANSFERPLANETARY GEAR
TR−33
1413 Author: Date:
1996 TOYOTA T100 (RM449U)
PLANETARY GEAR
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR028−02
TF0493
TF0494
TF0496
SST
Q06505
SST
SST
TF0498
TR−34
− TRANSFERPLANETARY GEAR
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT PINION GEAR THRUST CLEARANCE
Using a feeler gauge, measure the planetary pinion gear thrust
clearance.
Standard clearance:
0.11 − 0.86 mm (0.0043 − 0.0339 in.)
Maximum clearance: 0.86 mm (0.0339 in.)
If the clearance exceeds the maximum, replace the planetary
gear assembly
2. INSPECT PLANETARY PINION GEAR RADIAL
CLEARANCE
Using a dial indicator, measure the radial clearance of the plan-
etary pinion gear.
Standard clearance:
0.009 − 0.038 mm (0.0004 − 0.0015 in.)
Maximum clearance: 0.038 mm (0.0015 in.)
If the clearance exceeds the maximum, replace the planetary
gear assembly.
3. IF NECESSARY, REPLACE PLANETARY GEAR OUT-
ER BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the outer bearing.
SST 09554−30011, 09555−55010
(c) Using SST and a press, install a new bearing with the out-
er race snap ring groove the front.
SST 09223−15020, 09515−30010, 09550−22011
(09550−00020)
(d) Select a snap ring that will allow minimum axial play.
MarkThickness mm (in.)
11.45 − 1.50 (0.0571 − 0.0591)
21.50 − 1.55 (0.0591 − 0.0610)
31.55 − 1.60 (0.0610 − 0.0630)
41.60 − 1.65 (0.0630 − 0.0650)
51.65 − 1.70 (0.0650 − 0.0669)
(e) Using a snap ring expander, install the snap ring.

Downloaded from www.Manualslib.com manuals search engine TF0499
TF0538
− TRANSFERPLANETARY GEAR
TR−35
1996 TOYOTA T100 (RM449U)
4. IF NECESSARY, REPLACE PLANETARY GEAR INNER
BEARING
(a) Using SST and a press, remove the bearing.
SST 09550−10012 (09252−10010, 09557−10010)
(b) Using SST and a press, install a new bearing.
SST 09550−10012 (09252−10010, 09557−10010),
09515−30010
Bearing depth: 5.0 − 5.6 mm (0.197 − 0.220 in.)

Downloaded from www.Manualslib.com manuals search engine TR029−02
Q06959
 Oil Seal (for A/T)
Front CaseRear Case
Rear Companion Flange
 Oil Seal
Extension Housing
Front Companion Flange
 Non−reusable partFront Retainer
x5 x7 Oil Seal
 Oil Seal  Oil Seal
 Oil Seal O−ring TR−36
− TRANSFEROIL SEAL
1416 Author: Date:
1996 TOYOTA T100 (RM449U)
OIL SEAL
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR0D4−01
TF0500
TF0501
SST
TF0502
TF0503
SST
TF0504
− TRANSFEROIL SEAL
TR−37
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REPLACE FRONT RETAINER OIL SEAL
(a) Using a screwdriver and hammer, drive out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the retainer upper surface.
SST 09223−22010
(c) Coat the lip of the oil seal with MP grease.
2. REPLACE FRONT CASE OIL SEAL
(a) Using a screwdriver and hammer, drive out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the case upper surface.
SST 09316−60011 (09316−00011)
(c) Coat the lip of the oil seal with MP grease.
3. REPLACE EXTENSION HOUSING OIL SEAL
(a) Using a screwdriver and hammer, drive out the oil seal.

Downloaded from www.Manualslib.com manuals search engine TF0505
TF0506
TF0530
TF0631
TF0630
TR−38
− TRANSFEROIL SEAL
1996 TOYOTA T100 (RM449U)
(b) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the housing upper surface.
SST 09550−00032, 09550−10012 (09252−10010)
(c) Coat the lip of the oil seal with MP grease.
4. REPLACE FRONT AND REAR COMPANION FLANGE
OIL SEALS
(a) Using a screwdriver and hammer, drive out the oil seals
from the 2 flanges.
(b) Using a socket wrench and hammer, drive in a new oil
seal.
(c) Coat the lip of the oil seal with MP grease.
5. A/T:
REPLACE SHIFT FORK SHAFT OIL SEALS
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09304−12012
Oil seal depth: −0.5 − 0.5 mm (−0.020 − 0.020 in.)

Downloaded from www.Manualslib.com manuals search engine PR – PROPELLER SHAFT

TROUBLESHOOTING PR-1

PROPELLER SHAFT ASSEMBLY (2WD) PR-2
PROPELLER SHAFT ASSEMBLY (4WD) PR-10
SPIDER BEARING PR-18

Downloaded from www.Manualslib.com manuals search engine PR01F−01
− PROPELLER SHAFTTROUBLESHOOTING
PR−1
1419 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
1. Center support bearing (Worn) 2WD
4WD
2. Sleeve yoke spline (Worn) 2WD
4WD
3. Spider bearing (Worn or stuck) 2WD
4WDPR−5
PR−13
PR−5
PR−13
PR−5
PR−13
Vibration
1. Transmission extension housing rear bushing (Runout)
2. Sleeve yoke spline (Stuck) 2WD
4WD
3. Propeller shaft (Runout) 2WD
4WD
4. Propeller shaft (Imbalance) 2WD
4WD−
PR−5
PR−13
PR−5
PR−13
PR−5
PR−13

Downloaded from www.Manualslib.com manuals search engine Q06677
 TMC
Spider Bearing
Snap RingIntermediate ShaftSpacer
Center Support
Bearing Sleeve Yoke
Dust Cover
Flange Yoke
 DANA
Non−reusable part


Flange Yoke
 
Spider Bearing Snap Ring 

Intermediate Shaft
Center Support Bearing
Spacer
Spacer
Center Yoke
Spider
Sleeve Yoke
Dust Cover



Propeller Shaft


Flange Yoke

Propeller Shaft
Spacer
PR01G−05
PR−2
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (2WD)
1420 Author: Date:
1996 TOYOTA T100 (RM449U)
PROPELLER SHAFT ASSEMBLY (2WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine PR01H−01
R15507Matchmarks
R04164
SST
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (2WD)
PR−3
1996 TOYOTA T100 (RM449U)
REMOVAL
REMOVE PROPELLER SHAFT
(a) Place matchmarks on the differential and propeller shaft
flanges.
(b) Remove the 4 bolts, washers and nuts.
(c) Remove the 2 mounting bolts and center support bearing
from the frame crossmember.
(d) Pull out the propeller shaft yoke from the transmission.
(e) Insert SST in the transmission to prevent oil leakage.
SST 09325−40010