1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine MT04W−05
D10951
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−25
1280 Author: Date:
1996 TOYOTA T100 (RM449U)
OUTPUT SHAFT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine MT04X−01
Q06818
3rd 1st
Z03552
2nd
Z03553
RM0012
MT−26
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE
Measure the thrust clearance of each gear.
Standard clearance:
1st gear: 0.15 − 0.45 mm (0.0059 − 0.0177 in.)
2nd and 3rd gears: 0.10 − 0.25 mm (0.0039 − 0.0098 in.)
Maximum clearance:
1st gear: 0.50 mm (0.0197 in.)
2nd and 3rd gears: 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 gear:
0.020 − 0.073 mm (0.0008 − 0.0029 in.)
2nd and 3rd gears:
0.015 − 0.068 mm (0.0006 − 0.0027 in.)
Maximum clearance:
1st gear: 0.160 mm (0.0063 in.)
2nd and 3rd gears: 0.160 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE 5TH GEAR, OUTPUT SHAFT CENTER
BEARING AND 1ST GEAR ASSEMBLY
(a) Using a press, remove the 5th gear, center bearing, thrust
washer and 1st gear.
(b) Remove the synchronizer ring.
(c) Remove the straight pin and needle roller bearing.
(d) Remove the spacer.

Downloaded from www.Manualslib.com manuals search engine Z03548
Q00888
Z03550
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−27
1996 TOYOTA T100 (RM449U)
4. REMOVE REVERSE GEAR ASSEMBLY AND 2ND
GEAR ASSEMBLY
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
(b) Using a press, remove the reverse gear assembly and
2nd gear assembly.
(c) Remove the needle roller bearing.
5. REMOVE REVERSE GEAR, SHIFTING KEY AND
SPRING FROM CLUTCH HUB NO.1
(a) Remove the reverse gear from the clutch hub No.1.
(b) Push the shifting key spring with a screwdriver, remove
the 3 shifting keys and key springs.
6. REMOVE HUB SLEEVE NO.2 ASSEMBLY AND 3RD
GEAR ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the hub sleeve No.2 assembly and
3rd gear assembly.
(c) Remove the needle roller bearing.
7. REMOVE SHIFTING KEY AND SPRING FROM HUB
SLEEVE NO.2 ASSEMBLY
Using a screwdriver, remove the 3 shifting keys and 2 springs.

Downloaded from www.Manualslib.com manuals search engine Z03554
MT04Y−05
Z03555
AB
C
Z03556
WM0064
MT−28
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT OUTPUT SHAFT
(a) Using a micrometer, measure the output shaft flange
thickness.
Minimum thickness: 4.70 mm (0.1850 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
A 1st gear: 38.860 mm (1.5299 in.)
B 2nd gear: 46.860 mm (1.8449 in.)
C 3rd gear: 37.860 mm (1.4905 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.
(c) 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.
2. INSPECT 1ST AND 3RD GEARS 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.

Downloaded from www.Manualslib.com manuals search engine WM0065
Q00930
MT0780
D10952
WM0066
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−29
1996 TOYOTA T100 (RM449U)
(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.
3. INSPECT 2ND GEAR SYNCHRONIZER RING
(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.
(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.
4. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

Downloaded from www.Manualslib.com manuals search engine MT04Z−01
Q06699
Front
Q00888
Q06700
Front
Z03558
MT−30
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL CLUTCH HUB NO.2 INTO HUB SLEEVE NO.2
(a) Install the clutch hub No.2 and shifting keys to the hub
sleeve No.2.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not
aligned.
2. INSTALL CLUTCH HUB NO.1 INTO REVERSE GEAR
(a) Install the 3 shifting key springs to the clutch hub No.1.
(b) While pushing the shifting key spring with a screwdriver,
install the 3 shifting keys.
(c) While pushing the 3 shifting keys, install the clutch hub
No.1 to the reverse gear, as shown.
3. INSTALL 3RD GEAR AND HUB SLEEVE NO.2 ON
OUTPUT SHAFT
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Install the needle roller bearing in the 3rd gear.

Downloaded from www.Manualslib.com manuals search engine GM0060
WM0116
RM0023
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−31
1996 TOYOTA T100 (RM449U)
(d) Using a press, install the 3rd gear and hub sleeve No.2.
4. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A1.80 − 1.85 (0.0709 − 0.0728)
B1.85 − 1.90 (0.0728 − 0.0748)
C1.90 − 1.95 (0.0748 − 0.0768)
D1.95 − 2.00 (0.0768 − 0.0787)
E2.00 − 2.05 (0.0787 − 0.0807)
F2.05 − 2.10 (0.0807 − 0.0827)
G2.10 − 2.15 (0.0827 − 0.0846)
(b) Using a snap ring expander, install the snap ring.
5. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MT−26)
6. INSTALL 2ND GEAR AND REVERSE GEAR
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Align the projection of the synchronizer inner ring with the
slots of the clutch hub No.1.
(d) Install the needle roller bearing in the 2nd gear.
(e) Using a press, install the 2nd gear assembly and reverse
gear assembly.

Downloaded from www.Manualslib.com manuals search engine Z03560
Z03563
Z03564
Z03565
2WD: 4WD:
SST
SST MT−32
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
7. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.30 − 2.35 (0.0906 − 0.0925)
B2.35 − 2.40 (0.0925 − 0.0945)
C2.40 − 2.45 (0.0945 − 0.0965)
D2.45 − 2.50 (0.0965 − 0.0984)
E2.50 − 2.55 (0.0984 − 0.1004)
F2.55 − 2.60 (0.1004 − 0.1024)
G2.60 − 2.65 (0.1024 − 0.1043)
(b) Using a screwdriver and hammer, install the snap ring.
8. INSTALL SPACER AND 1ST GEAR ASSEMBLY
(a) Install the spacer on the output shaft.
(b) Apply gear oil to the needle roller bearing.
(c) Assemble the 1st gear, synchronizer ring and needle roll-
er bearing.
(d) Install the assembly on the output shaft with the synchro-
nizer ring slots aligned with the shifting keys.
9. INSTALL STRAIGHT PIN AND 1ST GEAR THRUST
WASHER
Install the 1st gear thrust washer onto the output shaft with the
straight pin aligned with the 1st gear thrust washer.
10. INSTALL OUTPUT SHAFT CENTER BEARING
(a) 2WD:
Using SST and a hammer, drive in the bearing with the
outer race snap ring groove toward the rear.
SST 09309−35010
(b) 4WD:
Using SST and a hammer, drive in the bearing with the
outer race snap ring groove toward the rear.
SST 09316−60011 (09316−00011, 09316−00071)