r150 TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine INDEX
IN Introduction
MA Maintenance
PP Preparation
SS Service Specifications
DI Diagnostics
EM Engine Mechanical (3RZ-FE)
Engine Mechanical (5VZ-FE)
EC Emissions Control (3RZ-FE)
Emissions Control (5VZ-FE)
MF MFI System (3RZ-FE)
SF SFI System (5VZ-FE)
CO Cooling (3RZ-FE)
Cooling (5VZ-FE)
LU Lubrication (3RZ-FE)
Lubrication (5VZ-FE)
IG Ignition (3RZ-FE)
Ignition (5VZ-FE)
ST Starting (3RZ-FE)
Starting (5VZ-FE)
CH Charging (3RZ-FE)
Charging (5VZ-FE)
CL Clutch
MT Manual Transmission (R150, R150F)
Manual Transmission (W59)
AT Automatic Transmission
TR Transfer
PR Propeller Shaft
SA Suspension and Axle
BR Brake
SR Steering
RS Supplemental Restraint System
BE Body Electrical
BO Body
AC Air Conditioning

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 PP – PREPARATION

MAINTENANCE PP-1
ENGINE MECHANICAL (3RZ-FE) PP-2
ENGINE MECHANICAL (5VZ-FE) PP-8
EMISSION CONTROL (3RZ-FE) PP-14
EMISSION CONTROL (5VZ-FE) PP-16
MFI (3RZ-FE) PP-19
SFI (5VZ-FE) PP-22
COOLING (3RZ-FE) PP-25
COOLING (5VZ-FE) PP-28
LUBRICATION (3RZ-FE) PP-33
LUBRICATION (5VZ-FE) PP-38
IGNITION (3RZ-FE) PP-43
IGNITION (5VZ-FE) PP-46
STARTING (3RZ-FE) PP-48
STARTING (5VZ-FE) PP-51
CHARGING (3RZ-FE) PP-54
CHARGING (5VZ-FE) PP-57
CLUTCH PP-60
MANUAL TRANSMISSION (R150,
R150F) PP-63
MANUAL TRANSMISSION (W59) PP-69
AUTOMATIC TRANSMISSION PP-75
TRANSFER PP-80
PROPELLER SHAFT PP-86
SUSPENSION AND AXLE PP-88
BRAKE PP-98
STEERING PP-103
SUPPLEMENTAL RESTRAINT SYSTEM PP-113
BODY ELECTRICAL PP-116
BODY PP-119
AIR CONDITIONING PP-122

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−64
− PREPARATIONMANUAL TRANSMISSION (R150, R150F)
11 3 Author: Date:
1996 TOYOTA T100 (RM449U)
(09951−00570)Replacer 57Extension housing oil seal
Transfer adaptor oil seal
(09951−00620)Replacer 62Counter rear bearing
09950−70010Handle Set
(09951−07150)Handle 150

Downloaded from www.Manualslib.com manuals search engine PP3LS−01
− PREPARATIONMANUAL TRANSMISSION (R150, R150F)
PP−65
1996 TOYOTA T100 (RM449U)
RECOMMENDED TOOLS
09031−00030Pin Punch .
09042−00020Torx Socket T40 .
09905−00012Snap Ring No.1 Expander .

Downloaded from www.Manualslib.com manuals search engine PP0ES−01
PP−66
− PREPARATIONMANUAL TRANSMISSION (R150, R150F)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Dial indicator
Micrometer
Torque wrench
Feeler gauge
Magnetic finger

Downloaded from www.Manualslib.com manuals search engine PP0ET−01
− PREPARATIONMANUAL TRANSMISSION (R150, R150F)
PP−67
1996 TOYOTA T100 (RM449U)
LUBRICANT
ItemCapacityClassification
Manual transmission oil2WD:
4WD:2.6 liters (2.7 US qts, 2.3 Imp. qts)
2.2 liters (2.3 US qts, 1.9 Imp. qts)API GL−4 or GL−5
SAE 75W−90