4WD TOYOTA T100 1996 Factory Repair Manual

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− LUBRICATION (5VZ−FE)OIL AND FILTER
1996 TOYOTA T100 (RM449U)
3. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
(b) Fill the engine with new oil.
Oil capacity
ItemCapacity
liters (US qts, lmp. qts)
Drain and refill
w/ Oil filter change 2WD
4WD
w/o Oil filter change 2WD
4WD
Dry fill 2WD
4WD
5.2 (5.5, 4.6)
4.7 (5.0, 4.1)
4.9 (5.2, 4.3)
4.4 (4.7, 3.9)
5.9 (6.2, 5.2)
5.5 (5.8, 4.8)
(c) Reinstall the oil filler cap.
4. START ENGINE AND CHECK FOR LEAKS
5. RECHECK ENGINE LEVEL

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Z04119
SST SST
P20974
P20973
− LUBRICATION (5VZ−FE)OIL PUMP
LU−9
1996 TOYOTA T100 (RM449U)
REMOVAL
HINT:
When repairing the oil pump, the oil pan and strainer should be
removed and cleaned.
1. REMOVE CRANKSHAFT TIMING PULLEY
(See page EM−13)
2. 4WD:
REMOVE FRONT DIFFERENTIAL
3. DRAIN ENGINE OIL
4. A/T:
REMOVE OIL COOLER TUBE AND CLAMP
(See page AT−28)
5. REMOVE STIFFENER PLATE
6. REMOVE FLYWHEEL HOUSING UNDER AND COVER
DUST
7. DISCONNECT STARTER WIRE CLAMP
8. REMOVE CRANKSHAFT POSITION SENSOR
9. REMOVE OIL PAN
(a) Remove the 15 bolts and 4 nuts.
(b) Using SST and a brass bar, separate the oil pan from the
cylinder block.
SST 09032−00100
HINT:
When removing the oil pan, be careful not to damage the oil pan
flange.
10. REMOVE OIL STRAINER
Remove the 2 bolts, 2 nuts and oil strainer and gasket.
11. REMOVE OIL PAN BAFFLE PLATE
Remove the 2 bolt, nut and oil pan baffle plate.
12. REMOVE OIL PUMP
(a) Remove the 8 bolts, ground strap and oil pump.
(b) Using a plastic−faced hammer, carefully tap the oil pump
body.
(c) Remove the O−ring from the cylinder block.

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− LUBRICATION (5VZ−FE)OIL PUMP
1996 TOYOTA T100 (RM449U)
12. 4WD:
INSTALL FRONT DIFFERENTIAL
(See page SA−68)
13. FILL WITH ENGINE OIL
14. START ENGINE AND CHECK FOR LEAKS
15. INSTALL ENGINE UNDER COVER
16. RECHECK ENGINE OIL LEVEL

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Push Rod Play Adjust Point
Pedal Height
Adjust Point
Pedal Height
Push Rod
PlayCL027−01
CL0102Pedal Freeplay CL−2
− CLUTCHCLUTCH PEDAL
1237 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH PEDAL
INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from floor panel:
154.6 − 164.6 mm (6.087 − 6.480 in.)
Pedal height from asphalt sheet:
Extra Cab (4WD): 150.1 − 160.1 mm (5.909 − 6.303 in.)
Others: 153.1 − 163.1 mm (6.027 − 6.421 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD
PLAY ARE CORRECT
Push in on the pedal until the beginning of clutch resis-
tance is felt.
Pedal freeplay: 5.0 − 15.0 mm (0.197 − 0.591 in.)
Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0 − 5.0 mm (0.039 − 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. CHECK CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears contact.

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Q06639
Matchmarks
Q06637
CL−16
− CLUTCHCLUTCH UNIT
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION FROM ENGINE
W59: See page MT−3
R150 (2WD): MT−3
R150F (4WD): MT−6
2. REMOVE CLUTCH COVER AND DISC
(a) Place matchmarks on the flywheel and clutch cover.
(b) Loosen each set bolt one turn at a time until spring tension
is released.
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
3. REMOVE BOOT, RELEASE BEARING AND FORK
FROM TRANSMISSION
Remove the boot and release bearing together with the fork and
then separate them.

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− CLUTCHCLUTCH UNIT
1996 TOYOTA T100 (RM449U)
5. INSTALL TRANSMISSION TO ENGINE
W59: See page MT−3
R150 (2WD): See page MT−3
R150F (4WD):See page MT−6

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MANUAL TRANSMISSION SYSTEM MT-1
TROUBLESHOOTING MT-2
MANUAL TRANSMISSION UNIT (2WD) MT-3
MANUAL TRANSMISSION UNIT (4WD) MT-6
MANUAL TRANSMISSION ASSEMBLY MT-11
INPUT SHAFT MT-22
OUTPUT SHAFT MT-25
COUNTER GEAR AND REVERSE
IDLER GEAR MT-34
FRONT BEARING RETAINER OIL SEAL MT-40
EXTENSION HOUSING AND
TRANSFER ADAPTOR MT-42

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MT−2
− MANUAL TRANSMISSION (R150, R150F)TROUBLESHOOTING
1257 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) 2WD
4WD
2. Oil (Wrong) 2WD
4WD
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−4
MT−7
MT−4
MT−7
MT−11
MT−11
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MT−4
MT−7
MT−11
MT−11
MT−11
Hard to shift or will not shift
1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)MT−22
MT−25
MT−34
MT−25
MT−34
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−11
MT−11
MT−11
MT−11

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D10949
MT−6
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
1261 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION UNIT (4WD)
COMPONENTS

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Down
ClothCounterclockwise
MT04O−02
Q06817
Installation
Front
Select Return Spring
Tip of Shift Lever
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
MT−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION SHIFT LEVER
(a) Remove the 4 screws and front console box.
(b) Remove the 4 screws and shift lever boot retainer.
(c) Cover the shift lever cap with a cloth.
(d) Then, pressing down on the shift lever cap, rotate it coun-
terclockwise to remove.
(e) Pull out the shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of the shift lever.
2. REMOVE TRANSFER SHIFT LEVER
Using snap ring pliers, remove the snap ring and pull out the
shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of shift lever.
3. RAISE VEHICLE AND DRAIN TRANSMISSION OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 2.2 liters (2.3 US qts, 1.9 Imp. qts)
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE FRONT AND REAR PROPELLER SHAFTS
(See page PR−10)
5. DISCONNECT SPEEDOMETER CABLE
6. DISCONNECT BACK−UP LIGHT SWITCH AND 4WD
INDICATOR SWITCH CONNECTORS
7. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
Remove the 4 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)