1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine D00863
Q06283
SST
D00864
Socket Wrench
Q00987
MT−12
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
16. REMOVE COUNTER REAR BEARING, SPACER,
COUNTER 5TH GEAR AND NEEDLE ROLLER BEAR-
ING
(a) Using a snap ring expander, remove 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.)
11.90 − 1.95 (0.0748 − 0.0768)
21.96 − 2.01 (0.0772 − 0.0791)
32.02 − 2.07 (0.0795 − 0.0815)
42.08 − 2.13 (0.0819 − 0.0839)
52.14 − 2.19 (0.0843 − 0.0862)
62.20 − 2.25 (0.0866 − 0.0886)
72.26 − 2.31 (0.0890 − 0.0909)
(b) Using SST, remove the rear bearing, spacer, counter 5th
gear and bearing.
SST 09950−40010
NOTICE:
Be careful not to catch the output shaft rear bearing roller
on the counter 5th gear.
(c) Remove the spacer.
HINT:
At the time of reassembly, please refer to the following items.
Install the counter 5th gear with the 5th gear gaps aligned
with the synchronizer cone ring pin.
Using a socket wrench and hammer, drive in the bearing.
When driving in the bearing, support the counter shaft in
front with a 1.4 − 2.3 kg (3 − 5 lb) hammer or equivalent.
17. REMOVE SYNCHRONIZER RING ASSEMBLY WITH
NO.3 HUB SLEEVE AND NO.3 CLUTCH HUB
(a) Remove the synchronizer ring assembly with the No.3
hub sleeve from the No.3 clutch hub.

Downloaded from www.Manualslib.com manuals search engine Q04007
Q06285
SST
D00865
SST Front
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−13
1996 TOYOTA T100 (RM449U)
(b) Remove the spacer.
(c) 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.)
22.06 − 2.11 (0.0811 − 0.0831)
32.12 − 2.17 (0.0835 − 0.0854)
42.18 − 2.23 (0.0858 − 0.0878)
52.24 − 2.29 (0.0882 − 0.0902)
(d) Using SST, remove the No.3 clutch hub.
SST 09950−40010
HINT:
At the time of reassembly, please refer to the following items.
Using SST and a hammer, drive in the No.3 clutch hub.
SST 09316−60011 (09316−00011, 09316−00071)
When installing the No.3 clutch hub, support the counter
shaft in front with a 1.4 − 2.3 kg (3 − 5 lb) hammer or equiv-
alent.
18. REMOVE REAR MAGNET

Downloaded from www.Manualslib.com manuals search engine D00866
WM0046
SST
D00867
SSTSST
MT−14
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
19. REMOVE OUTPUT SHAFT REAR BEARING AND 5TH
GEAR
(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.)
82.31 − 2.36 (0.0909 − 0.0929)
92.37 − 2.42 (0.0933 − 0.0953)
102.43 − 2.48 (0.0957 − 0.0976)
112.49 − 2.54 (0.0980 − 0.1000)
122.55 − 2.60 (0.1004 − 0.1024)
132.61 − 2.66 (0.1028 − 0.1047)
142.68 − 2.73 (0.1055 − 0.1075)
152.74 − 2.79 (0.1079 − 0.1098)
(b) Using SST, remove the rear bearing and 5th gear.
SST 09312−20011 (09313−00030, 09313−00040,
09313−00050)
HINT:
At the time of reassembly. please refer to the following item.
Using SST, install the 5th gear and rear bearing.
SST 09312−20011 (09313−00010, 09313−00030,
09313−00040, 09313−00050)

Downloaded from www.Manualslib.com manuals search engine D00868
Q05168
SST
D00870
SST
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−15
1996 TOYOTA T100 (RM449U)
20. REMOVE REVERSE GEAR
(a) Using a snap ring expander, remove 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.)
52.25 − 2.30 (0.0886 − 0.0906)
112.30 − 2.35 (0.0906 − 0.0925)
122.35 − 2.40 (0.0925 − 0.0945)
132.40 − 2.45 (0.0945 − 0.0965)
142.45 − 2.50 (0.0965 − 0.0984)
152.50 − 2.55 (0.0984 − 0.1004)
162.55 − 2.60 (0.1004 − 0.1024)
172.61 − 2.66 (0.1028 − 0.1047)
182.67 − 2.72 (0.1051 − 0.1071)
192.73 − 2.78 (0.1075 − 0.1094)
202.79 − 2.84 (0.1098 − 0.1118)
212.85 − 2.90 (0.1122 − 0.1142)
222.91 − 2.96 (0.1146 − 0.1165)
232.97 − 3.02 (0.1169 − 0.1189)
(b) Using SST, remove the reverse gear.
SST 09950−40010
HINT:
At the time of reassembly, please refer to the following item.
Using SST, install the reverse gear.
SST 09312−20011 (09313−00030, 09313−00040,
09313−00050)
21. REMOVE REAR BEARING RETAINER
(a) Using a torx socket wrench (T40), unscrew the 4 torx
screws and remove the rear bearing retainer.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Q00855
Q07367
SST
WM0125
SST
Q07552
SSTSST
25mm MT−16
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
(b) Using a snap ring expander, remove the 2 snap rings.
HINT:
At the time of reassembly, please refer to the following item.
Make sure the snap ring is flush with the intermediate plate sur-
face.
22. REMOVE OUTPUT SHAFT AND COUNTER GEAR
FROM INTERMEDIATE PLATE
(a) Remove the output shaft, input shaft and counter gear 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 from the output shaft.
HINT:
At the time of reassembly, please refer to the following items.
Before installing the output shaft, use SST to remove the
counter gear center bearing outer race.
SST 09950−60010 (09951−00510), 09950−70010
(09951−07150)
Install the outer race after installing the counter gear.
Install the output shaft into the intermediate plate by pull-
ing on the output shaft and tapping on the intermediate
plate.
HINT:
At the time of reassembly, please refer to the following items.
Apply gear oil to the needle roller bearing.
Install the needle roller bearing to the input shaft.
Install the input shaft and counter gear together.
Using SST and a hammer, install a new counter gear cen-
ter bearing outer race.
SST 09316−60011 (09316−00011)
Be careful not to damage the bearing rollers.
23. 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 MT03O−02
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−17
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MT−8).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

Downloaded from www.Manualslib.com manuals search engine MT03P−01
Q00884
Snap Ring
Snap RingBearingInput ShaftSynchronizer Ring Roller Bearing
Non−reusable part  MT−18
− MANUAL TRANSMISSION (W59)INPUT SHAFT
1317 Author: Date:
1996 TOYOTA T100 (RM449U)
INPUT SHAFT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine D00871
MT03Q−01
D00872
− MANUAL TRANSMISSION (W59)INPUT SHAFT
MT−19
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: 0.5 mm (0.020 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.