replace manual transmission TOYOTA T100 1996 Factory Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Z03540
RM0010
Q07393
SST
Q07552
SST
SST
25 mm MT−20
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
30. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft toward the rear.
HINT:
At the time of the reassembly, please refer to the following item.
Align the reverse shift arm to the reverse idler gear shaft.
31. REMOVE OUTPUT SHAFT CENTER BEARING SNAP
RING
Using a snap ring expander, remove the snap ring.
32. REMOVE OUTPUT SHAFT AND COUNTER GEAR
FROM INTERMEDIATE PLATE
(a) Remove the output shaft, counter gear and input shaft as
a unit from the intermediate plate by pulling on the counter
gear and tapping on the intermediate plate with a plastic
hammer.
(b) Remove the input shaft with the needle roller bearing from
the output shaft.
33. REMOVE COUNTER REAR BEARING FROM INTER-
MEDIATE PLATE
Using SST and a hammer, remove the counter rear bearing.
SST 09950−60010 (09951−00620), 09950−70010
(09951−07150)
34. 2WD:
IF NECESSARY, REPLACE SPEEDOMETER DRIVEN
GEAR OIL SEAL
(a) Using SST, remove the oil seal.
SST 09921−00010
(b) Coat the lip of oil seal with MP grease.
(c) Using SST, drive in a new oil seal.
SST 09201−10000 (09201−01080), 09950−70010
(09951−07150)
Drive in depth: 25 mm (0.98 in.)

Downloaded from www.Manualslib.com manuals search engine Q00550
MT04U−01
Z03541
− MANUAL TRANSMISSION (R150, R150F)INPUT SHAFT
MT−23
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.

Downloaded from www.Manualslib.com manuals search engine MT04V−01
Z03543
Z03544
SST
Z03545
MT−24
− MANUAL TRANSMISSION (R150, R150F)INPUT SHAFT
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the bearing.
(c) Using SST and a press, install a new bearing.
SST 09506−35010
(d) Select a snap ring that allows minimum 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)
(e) Using a snap ring expander, install the snap ring.

Downloaded from www.Manualslib.com manuals search engine MT04X−01
Q06818
3rd 1st
Z03552
2nd
Z03553
RM0012
MT−26
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE
Measure the thrust clearance of each gear.
Standard clearance:
1st gear: 0.15 − 0.45 mm (0.0059 − 0.0177 in.)
2nd and 3rd gears: 0.10 − 0.25 mm (0.0039 − 0.0098 in.)
Maximum clearance:
1st gear: 0.50 mm (0.0197 in.)
2nd and 3rd gears: 0.30 mm (0.0118 in.)
2. INSPECT EACH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of each
gear.
Standard clearance:
1st gear:
0.020 − 0.073 mm (0.0008 − 0.0029 in.)
2nd and 3rd gears:
0.015 − 0.068 mm (0.0006 − 0.0027 in.)
Maximum clearance:
1st gear: 0.160 mm (0.0063 in.)
2nd and 3rd gears: 0.160 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE 5TH GEAR, OUTPUT SHAFT CENTER
BEARING AND 1ST GEAR ASSEMBLY
(a) Using a press, remove the 5th gear, center bearing, thrust
washer and 1st gear.
(b) Remove the synchronizer ring.
(c) Remove the straight pin and needle roller bearing.
(d) Remove the spacer.

Downloaded from www.Manualslib.com manuals search engine Z03554
MT04Y−05
Z03555
AB
C
Z03556
WM0064
MT−28
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT OUTPUT SHAFT
(a) Using a micrometer, measure the output shaft flange
thickness.
Minimum thickness: 4.70 mm (0.1850 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
A 1st gear: 38.860 mm (1.5299 in.)
B 2nd gear: 46.860 mm (1.8449 in.)
C 3rd gear: 37.860 mm (1.4905 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)
If the runout exceeds the maximum, replace the output shaft.
2. INSPECT 1ST AND 3RD GEARS SYNCHRONIZER
RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.

Downloaded from www.Manualslib.com manuals search engine WM0065
Q00930
MT0780
D10952
WM0066
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−29
1996 TOYOTA T100 (RM449U)
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
3. INSPECT 2ND GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer inner ring, middle ring and outer
ring to each gear.
(c) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
4. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
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 MT052−01
Z03569
Q06689
Q06831
Q06832
MT−36
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Install the spacer, counter 5th gear and needle roller bear-
ings.
(b) Using a dial indicator, measure the counter 5th gear radial
clearance.
Standard clearance:
0.015 − 0.068 mm (0.0006 − 0.0027 in.)
Maximum clearance:
0.160 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the gear bear-
ing or shaft.
2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter
gear journal.
Minimum diameter: 27.860 mm (1.0968 in.)
If the outer diameter is less than the minimum, replace the
counter gear.
3. INSPECT 5TH SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer pull ring, cone ring and outer ring
to the gear spline piece No.5.
(c) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.

Downloaded from www.Manualslib.com manuals search engine WM0066
Q01803
Q06775
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
MT−37
1996 TOYOTA T100 (RM449U)
4. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
5. INSPECT REVERSE IDLER GEAR RADIAL CLEAR-
ANCE
Using a dial indicator, measure the reverse idler gear radial
clearance.
Standard clearance:
0.040 − 0.082 mm (0.0016 − 0.0032 in.)
Maximum clearance:
0.130 mm (0.0051 in.)
If the clearance exceeds the maximum, replace the reverse
idler gear or reverse idler gear shaft.
6. INSPECT REVERSE IDLER GEAR AND SHIFT ARM
CLEARANCE
Using a feeler gauge, measure the clearance between the re-
verse idler gear and shift arm.
Standard clearance:
0.05 − 0.35 mm (0.0020 − 0.0138 in.)
Maximum clearance:
0.50 mm (0.0197 in.)
If the clearance exceeds the maximum, replace the shift arm or
reverse idler gear.

Downloaded from www.Manualslib.com manuals search engine MT053−01
Z03575
SST
RM0013
Socket Wrench
Z03576
MT−38
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE COUNTER GEAR FRONT
BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the bearing.
SST 09950−00020
(c) Replace the side race.
(d) Using a socket wrench and press, install a new bearing
and side race.
(e) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.00 − 2.05 (0.0787 − 0.0807)
B2.05 − 2.10 (0.0807 − 0.0827)
C2.10 − 2.15 (0.0827 − 0.0846)
D2.15 − 2.20 (0.0846 − 0.0866)
E2.20 − 2.25 (0.0866 − 0.0886)
F2.25 − 2.30 (0.0886 − 0.0906)
(f) Using a snap ring expander, install the snap ring.

Downloaded from www.Manualslib.com manuals search engine MT056−01
Z03583
Q07394
SST
− MANUAL TRANSMISSION (R150, R150F)FRONT BEARING RETAINER OIL SEAL
MT−41
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE FRONT BEARING RETAINER
OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00510), 09950−70010
(09951−07150)
Drive in depth:
11.7 ± 0.5 mm (0.461 ± 0.020 in.) from retainer end