1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine RM0063
RM0072
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−17
1996 TOYOTA T100 (RM449U)
22. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and reverse shift arm bracket.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
23. 2WD:
REMOVE SPEEDOMETER DRIVE GEAR
(a) Using 2 screwdrivers and a hammer, tap out the rear snap
ring, and remove the drive gear and ball.
(b) Using 2 screwdrivers and a hammer, tap out the front
snap ring, and remove the drive gear.
24. REMOVE OUTPUT SHAFT REAR BEARING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.65 − 2.70 (0.1043 − 0.1063)
B2.70 − 2.75 (0.1063 − 0.1083)
C2.75 − 2.80 (0.1083 − 0.1102)
D2.80 − 2.85 (0.1102 − 0.1122)
E2.85 − 2.90 (0.1122 − 0.1142)
F2.90 − 2.95 (0.1142 − 0.1161)
G2.95 − 3.00 (0.1161 − 0.1181)
H3.00 − 3.05 (0.1181 − 0.1201)
J3.05 − 3.10 (0.1201 − 0.1220)
K3.10 − 3.15 (0.1220 − 0.1240)
L3.15 − 3.20 (0.1240 − 0.1260)
M3.20 − 3.25 (0.1260 − 0.1280)
N3.25 − 3.30 (0.1280 − 0.1299)
P3.30 − 3.35 (0.1299 − 0.1319)
Q3.35 − 3.40 (0.1319 − 0.1339)
R3.40 − 3.45 (0.1339 − 0.1358)
S3.45 − 3.50 (0.1358 − 0.1378)

Downloaded from www.Manualslib.com manuals search engine Z14821
SST 4WD:
Z14820
SST
2WD:
RM0070
SST 2WD:
RM0071
SST 4WD:
Q06786
MT−18
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
(b) Using SST, remove the rear bearing.
SST 09950−40010
HINT:
At the time of reassembly, please refer to the following items.
2WD:
Using SST and a hammer, drive in a new bearing.
SST 09309−35010
4WD:
Using SST and a hammer, drive in a new bearing.
SST 09316−60011 (09316−00011, 09316−00071)
25. REMOVE SPACER
26. INSPECT COUNTER 5TH GEAR THRUST CLEAR-
ANCE
Using a feeler gauge, measure the counter 5th gear thrust
clearance.
Standard clearance:
0.10 − 0.35 mm (0.0039 − 0.0138 in.)
Maximum clearance:
0.40 mm (0.0157 in.)

Downloaded from www.Manualslib.com manuals search engine Q06688
Q06605
SST
RM0024
SST
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−19
1996 TOYOTA T100 (RM449U)
27. REMOVE GEAR SPLINE PIECE NO.5, SYNCHRONIZ-
ER RING, NEEDLE ROLLER BEARING AND COUNT-
ER 5TH GEAR WITH HUB SLEEVE NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.80 − 2.85 (0.1102 − 0.1122)
B2.85 − 2.90 (0.1122 − 0.1142)
C2.90 − 2.95 (0.1142 − 0.1161)
D2.95 − 3.00 (0.1161 − 0.1181)
E3.00 − 3.05 (0.1181 − 0.1201)
F3.05 − 3.10 (0.1201 − 0.1220)
G3.10 − 3.15 (0.1220 − 0.1240)
(b) Using SST, remove the gear spline piece No.5.
SST 09950−50010
(c) Remove the counter 5th gear with the hub sleeve No.3.
HINT:
At the time of reassembly, please refer to the following items.
Using SST and a hammer, drive in the gear spline piece
No.5 with the synchronizer ring slots aligned with the shift-
ing keys.
SST 09316−60011 (09316−00011)
When installing the gear spline piece No.5, support the
counter gear in front with a 1.4 − 2.3 kg (3 − 5 lb) hammer
or equivalent.
28. REMOVE THRUST WASHER AND BALL FROM
COUNTER GEAR
29. REMOVE REAR BEARING RETAINER
Remove the 4 bolts and rear bearing retainer.
HINT:
At the time of reassembly, please refer to the following item.
Align the rear bearing retainer to the reverse idler gear shaft
groove.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

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 MT04S−05
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−21
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MT−13).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

Downloaded from www.Manualslib.com manuals search engine MT04T−01
WM0301
Snap Ring
 Bearing
Input ShaftBearing
Synchronizer Ring
 Non−reusable part MT−22
− MANUAL TRANSMISSION (R150, R150F)INPUT SHAFT
1277 Author: Date:
1996 TOYOTA T100 (RM449U)
INPUT SHAFT
COMPONENTS

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.