replace manual transmission TOYOTA T100 1996 Factory Workshop Manual

Downloaded from www.Manualslib.com manuals search engine MT057−01
Q04410
Z03582
Q07365
SST
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
MT−43
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Remove the reverse restrict pin.
(1) Using a torx socket wrench (T40), remove the screw
plug.
(2) Using a pin punch and hammer, drive out the slotted
spring pin.
(3) Remove the reverse restrict pin.
(b) Inspect the reverse restrict pin.
Turn and push the reverse restrict pin by hand.
Check for smooth operation.
(c) Install the reverse restrict pin.
(1) Install the reverse restrict pin to the extension hous-
ing or transfer adaptor.
(2) Using a pin punch and hammer, drive in the slotted
spring pin, as shown.
(3) Apply sealant to the plug threads.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(4) Using a torx socket wrench (T40), install and torque
the screw plug.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
2. 2WD:
IF NECESSARY, REPLACE EXTENSION HOUSING
OIL SEAL
(a) Remove the dust deflector.
(b) Using a screwdriver, pry out the oil seal.
(c) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00570), 09950−70010
(09951−07150)
Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(d) Install the deflector.

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SST
MT−44
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
1996 TOYOTA T100 (RM449U)
3. 4WD:
IF NECESSARY, REPLACE TRANSFER ADAPTOR 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 (09951−00570), 09950−70010
(09951−07150)
Drive in depth: 45.6 ± 0.5 mm (1.795 ± 0.020 in.)

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MT−2
− MANUAL TRANSMISSION (W59)TROUBLESHOOTING
1301 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. Oil (Level low)
2. Oil (Wrong)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−4
MT−4
MT−6
MT−6
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MT−4
MT−6
MT−6
MT−6
Hard to shift or will not shift
1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)MT−18
MT−21
MT−30
MT−18
MT−21
MT−30
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−6
MT−6
MT−6
MT−6

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Q07367
SST
WM0125
SST
Q07552
SSTSST
25mm MT−16
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
(b) Using a snap ring expander, remove the 2 snap rings.
HINT:
At the time of reassembly, please refer to the following item.
Make sure the snap ring is flush with the intermediate plate sur-
face.
22. REMOVE OUTPUT SHAFT AND COUNTER GEAR
FROM INTERMEDIATE PLATE
(a) Remove the output shaft, input shaft and counter gear 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 from the output shaft.
HINT:
At the time of reassembly, please refer to the following items.
Before installing the output shaft, use SST to remove the
counter gear center bearing outer race.
SST 09950−60010 (09951−00510), 09950−70010
(09951−07150)
Install the outer race after installing the counter gear.
Install the output shaft into the intermediate plate by pull-
ing on the output shaft and tapping on the intermediate
plate.
HINT:
At the time of reassembly, please refer to the following items.
Apply gear oil to the needle roller bearing.
Install the needle roller bearing to the input shaft.
Install the input shaft and counter gear together.
Using SST and a hammer, install a new counter gear cen-
ter bearing outer race.
SST 09316−60011 (09316−00011)
Be careful not to damage the bearing rollers.
23. 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.)

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MT03Q−01
D00872
− MANUAL TRANSMISSION (W59)INPUT SHAFT
MT−19
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: 0.5 mm (0.020 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.

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Q00857
Q00878
SST
Q00858
MT−20
− MANUAL TRANSMISSION (W59)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 the minimum axial play.
MarkThickness mm (in.)
12.05 − 2.10 (0.0807 − 0.0827)
22.10 − 2.15 (0.0827 − 0.0846)
32.15 − 2.20 (0.0846 − 0.0866)
42.20 − 2.25 (0.0866 − 0.0886)
52.25 − 2.30 (0.0886 − 0.0906)
112.30 − 2.35 (0.0906 − 0.0925)
122.35 − 2.40 (0.0925 − 0.0945)
(e) Using a snap ring expander, install the snap ring.

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Q00880
3rd
2nd 1st
D00873
3rd
2nd
1st
Q00859
WM0053
MT−22
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of each
gear.
Standard clearance:
0.10 − 0.25 mm (0.0039 − 0.0098 in.)
Maximum clearance:
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 and 2nd gears:
0.009 − 0.060 mm (0.0004 − 0.0024 in.)
3rd gear:
0.015 − 0.066 mm (0.0006 − 0.0026 in.)
Maximum clearance:
1st and 2nd gears:
0.150 mm (0.0059 in.)
3rd gear:
0.200 mm (0.0079 in.)
If the clearance exceeds the maximum, replace the gear, shaft
or needle roller bearing.
3. REMOVE OUTPUT SHAFT CENTER BEARING AND
1ST GEAR ASSEMBLY
(a) Shift the No.1 hub sleeve onto the 2nd gear.
(b) Using a press, remove the center bearing, 1st gear,
needle roller bearing, inner race and synchronizer ring.
4. REMOVE LOCKING BALL ON OUTPUT SHAFT
Using a magnetic finger, remove the locking ball.
5. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 2ND GEAR
AND NEEDLE ROLLER BEARING
Using a press, remove the parts from the shaft as an assembly.

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MT03U−01
WM0065
Q00930
MT0780
MT−24
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT 1ST GEAR 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: 0.5 mm (0.020 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.
2. INSPECT 2ND AND 3RD GEAR SYNCHRONIZER
RINGS
(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.

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WM0066
Q00860
Q00861
Q00862
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−25
1996 TOYOTA T100 (RM449U)
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and the gear spline end.
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
3. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeves and shift forks.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
4. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using vernier calipers, measure the output shaft flange
thickness.
Minimum thickness: 5.60 mm (0.2205 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using vernier calipers, measure the inner race flange
thickness.
Minimum thickness: 4.78 mm (0.1881 in.)
If the thickness is less than the minimum, replace the inner race.
(c) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
2nd gear: 42.975 mm (1.6919 in.)
3rd gear: 31.969 mm (1.2586 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.

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Q00864
MT−26
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
(d) Using a micrometer, measure the outer diameter of the in-
ner race.
Minimum diameter: 42.975 mm (1.6919 in.)
If the outer diameter is less than the minimum, replace the inner
race.
(e) 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.