differential TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine IN02G−02
B01123
[2WD]
[4WD]
JACK POSITION
SUPPORT POSITIONFront Center of crossmember
Rear Under the rear differential
Safety stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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IN−8
− INTRODUCTIONREPAIR INSTRUCTIONS
1996 TOYOTA T100 (RM449U)
VEHICLE LIFT AND SUPPORT LOCATIONS

Downloaded from www.Manualslib.com manuals search engine IN02L−01
− INTRODUCTIONTERMS
IN−31
31 Author: Date:
1996 TOYOTA T100 (RM449U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti−Lock Brake System
A.D.D.Automatic Disconnecting Differential
A/TAutomatic Transmission
AT FAutomatic Transmission Fluid
BTDCBefore Top Dead Center
Calif.California
CBCircuit Breaker
Diff.LockDifferential Locking System
DPDash Pot
ECUElectronic Control Unit
E/GEngine
ELREmergency Locking Retractor
ESAElectronic Spark Advance
EXExhaust (Manifold, Valve)
FIPGFormed in Place Gasket
FLFusible Link
FPUFuel Pressure Up
FrFront
IGIgnition
INIntake (Manifold, Valve)
J/BJunction Block
LHLeft−Hand
LLCLong Life Coolant (Year Around Coolant)
LSPVLoad Sensing Proportioning Valve
Max.Maximum
Min.Minimum
MPMultipurpose
M/TManual Transmission
O/D, ODOverdrive
OHCOver Head Camshaft
O/SOversize
PCVPositive Crankcase Ventilation
PSPower Steering
RHRight−Hand
RrRear
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
SWSwitch
TDCTop Dead Center
TEMP.Temperature

Downloaded from www.Manualslib.com manuals search engine IN−34
− INTRODUCTIONTERMS
1996 TOYOTA T100 (RM449U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module−
IFIIndirect Fuel InjectionIndirect Injection
IFSInertia Fuel−Shutoff−
ISCIdle Speed Control−
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure−
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface Temperature−
MVZManifold Vacuum Zone−
NVRAMNon−Volatile Random Access Memory−
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn−Board DiagnosticOn−Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module−
PNPPark/Neutral Position−
PROMProgrammable Read Only Memory−
PSPPower Steering Pressure−
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module−
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass−
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter−
SRIService Reminder Indicator−
SRTSystem Readiness Test−
STScan Tool−
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

Downloaded from www.Manualslib.com manuals search engine B02091
Z04824
A/T
OK if coolOK if hot
Add if coolAdd if hot
B02092
B02093
− MAINTENANCECHASSIS
MA−9
44 Author: Date:
1996 TOYOTA T100 (RM449U)
6. 2WD:
CHECK OIL LEVEL IN MANUAL TRANSMISSION, AU-
TOMATIC TRANSMISSION AND DIFFERENTIAL
(a) Manual transmission:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Transmission oil (M/T):
R150: See page MT−5
W59: See page MT−5
(b) Automatic transmission:
Check that the fluid level is in the ”HOT” range at the nor-
mal operating temperature (70 − 80°C or 158 − 176°F)
and add as necessary.
NOTICE:
Do not overfill.
Transmission fluid (A/T): See page
DI−265
(c) Differential:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Differential oil: See page SA−154
7. 5VZ−FE (4WD):
CHECK OIL LEVEL IN MANUAL TRANSMISSION, AU-
TOMATIC TRANSMISSION, TRANSFER AND DIFFER-
ENTIAL
(a) Manual transmission:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Transmission oil (M/T):
R150F: See page MT−10

Downloaded from www.Manualslib.com manuals search engine Z04824
A/T
OK if coolOK if hot
Add if coolAdd if hot
B02094
B02095
MA−10
− MAINTENANCECHASSIS
45 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) Automatic transmission:
Check that the fluid level is in the ”HOT” range at the nor-
mal operating temperature (70 − 80°C or 158 − 176°F)
and add as necessary.
NOTICE:
Do not overfill.
Transmission fluid (A/T): See page
DI−265
(c) Transfer:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Transfer oil: See page TR−3
(d) Differential:
Remove the filler plug and feel inside the hole with your
finger. Check that the oil comes to within 5 mm (0.20 in.)
of the bottom edge of the hole. If the level is low, add oil
until it begins to run out of the filler hole.
Front differential oil: See page SA−43
Rear differential oil: See page SA−154
8. REPLACE MANUAL TRANSMISSION, TRANSFER
(5VZ−FE: 4WD) AND DIFFERENTIAL OIL
(a) Transfer:
Remove the transfer cover.
(b) Remove the drain plug and drain the oil.
(c) Reinstall drain plug securely.
(d) Add new oil until it begins to run out of the filler hole.
(2WD) Transmission oil (M/T):
R150: See page MT−5
W59: See page MT−5

Downloaded from www.Manualslib.com manuals search engine B02096
B02097
B02098
2WD
4WD
− MAINTENANCECHASSIS
MA−11
46 Author: Date:
1996 TOYOTA T100 (RM449U)
(5VZ−FE: 4WD) Transmission oil (M/T):
R150F: See page MT−10
Transfer oil: See page
TR−3
Front differential oil: See page SA−43
Rear differential oil: See page SA−154
9. REPLACE AUTOMATIC TRANSMISSION FLUID
(a) Remove the drain plug(s) and drain the fluid.
(b) Reinstall the drain plug(s) securely.
(c) With the engine OFF, add new fluid through the dipstick
tube.
Transmission fluid (A/T): See page DI−265
(d) Start the engine and shift the selector into all positions
from ”P” through ”L” and then shift into ”P”.
(e) With the engine idling, check the fluid level.
Add fluid up to the ”COOL” level on the dipstick.

Downloaded from www.Manualslib.com manuals search engine PP3LR−01
− PREPARATIONMANUAL TRANSMISSION (R150, R150F)
PP−63
11 2 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION (R150, R150F)
SST (Special Service Tools)
09201−10000Valve Guide Bushing Remover &
Replacer Set2WD:
Speedometer driven gear oil seal
(09201−01080)Valve Guide Bushing Remover &
Replacer 8
09309−35010Transmission Rear Bearing
Replacer2WD:
Output shaft rear bearing
Output shaft center bearing
09316−60011Transmission & Transfer Bearing
Replacer
(09316−00011)Replacer PipeOutput shaft rear bearing
Gear spline piece No.5
(09316−00031)Replacer ”B”5th gear
(09316−00071)Replacer ”F”4WD:
Output shaft rear bearing
Output shaft center bearing
09506−35010Differential Drive Pinion Rear
Bearing ReplacerInput shaft bearing
09921−00010Spring Tension Tool2WD:
Speedometer driven gear oil seal
09950−00020Bearing Remover
09950−60010Replacer Set
(09951−00510)Replacer 51Front bearing retainer oil seal

Downloaded from www.Manualslib.com manuals search engine PP−70
− PREPARATIONMANUAL TRANSMISSION (W59)
11 9 Author: Date:
1996 TOYOTA T100 (RM449U)
09506−35010Differential Drive Pinion Rear
Bearing ReplacerInput shaft bearing
Output shaft center bearing
09921−00010Spring Tension ToolSpeedometer driven gear oil seal
09950−00020Bearing Remover
09950−60010Replacer Set
(09951−00440)Replacer 44Front bearing retainer oil seal
(09951−00510)Replacer 51Counter gear center bearing outer
race
(09951−00560)Replacer 56Output shaft rear bearing outer race
Extension housing oil seal
09950−70010Handle Set
(09951−07150)Handle 150

Downloaded from www.Manualslib.com manuals search engine PP3M7−01
PP−80
− PREPARATIONTRANSFER
129 Author: Date:
1996 TOYOTA T100 (RM449U)
TRANSFER
SST (Special Service Tools)
09223−15020Oil Seal & Bearing ReplacerPlanetary gear outer bearing
09223−22010Crankshaft Front Oil Seal
ReplacerFront retainer oil seal
09304−12012Input Shaft Front Bearing
ReplacerShift fork shaft oil seal
09316−60011Transmission & Transfer Bearing
Replacer
(09316−00011)Replacer PipeHigh and low clutch hub
Rear output shaft bearing
Front case oil seal
(09316−00071)Replacer ”F”Rear output shaft bearing
09330−00021Companion Flange Holding ToolCompanion flange
09515−30010Rear Wheel Bearing ReplacerPlanetary gear outer bearing
(09252−10010)No. 1 Replacer Handle
09550−00032Replacer
09554−30011Differential Oil Seal ReplacerPlanetary gear outer bearing
09555−55010Differential Drive Pinion
Bearing ReplacerPlanetary gear outer bearing

Downloaded from www.Manualslib.com manuals search engine PP3K7−01
PP−88
− PREPARATIONSUSPENSION AND AXLE
137 Author: Date:
1996 TOYOTA T100 (RM449U)
SUSPENSION AND AXLE
SST (Special Service Tools)
09223−56010Crankshaft Rear Oil Seal
ReplacerRear axle
09226−10010Crankshaft Front & Rear Bearing
ReplacerFront differential
09308−00010Oil Seal PullerFront axle (4WD)
Front differential
Rear axle
Rear differential
09316−12010Transfer Bearing ReplacerRear differential
09316−20011Transfer Bearing ReplacerFront differential
09316−60011Transmission & Transfer Bearing
ReplacerFront deifferentian
Rear axle
(09316−00041)Replacer ”C”Front differential
(09316−00051)Replacer ”D”Rear axle
09330−00021Companion Flange Holding ToolFront differential
Rear differential
09350−20015TOYOTA Automatic Transmission
Tool SetFront differential
(09369−20040)Piston Spring Compressor Set
09308−10010Oil Seal PullerFront differential
Rear differential