1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine TR01P−01
− TRANSFERTRANSFER SYSTEM
TR−1
1381 Author: Date:
1996 TOYOTA T100 (RM449U)
TRANSFER SYSTEM
PRECAUTION
When working with FIPG material, you must be observe the following.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non−residue solvent.
Apply the FIPG in approx. a 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.

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TR−2
− TRANSFERTROUBLESHOOTING
1382 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
1. Oil (Level low)
2. Oil (Wrong)
3. Transfer faulty−
−
TR−5
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−ring (Worn or damaged)−
−
TR−36
TR−36
Tight corner brakingCenter differential or transfer faultyTR−5

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TF0626
Breather Hose
Transmission Side Transfer Side
TF0633
TF0655
TF0654
− TRANSFERTRANSFER UNIT
TR−3
1383 Author: Date:
1996 TOYOTA T100 (RM449U)
TRANSFER UNIT
REMOVAL
1. REMOVE TRANSFER WITH TRANSMISSION
M/T (See page MT−7)
A/T (See page AT−34)
HINT:
At the time of installation, shift the 2 shift fork shafts to the H4
position.
2. A/T:
REMOVE BREATHER HOSE
Disconnect the breather hose from transfer upper cover and
transmission control retainer.
Hose depth: 13 mm (0.51 in.) or more
3. REMOVE DYNAMIC DAMPER
Remove the 2 bolts and dynamic damper.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the trans-
mission.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
5. REMOVE PROPELLER SHAFT UPPER DUST COVER
AND TRANSFER FROM TRANSMISSION
(a) Remove the dust cover bolt from the bracket.
Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)
(b) Remove the transfer adapter rear mounting bolts.
(c) Pull the transfer straight up and remove it from the trans-
mission.
HINT:
Take care not to damage the adaptor rear oil seal with the trans-
fer input gear spline.

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TR−4
− TRANSFERTRANSFER UNIT
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page TR−3).
1. APPLY MP GREASE TO TRANSFER ADAPTOR OIL SEAL
2. AFTER INSTALLATION, DO ROAD TEST

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− TRANSFERTRANSFER ASSEMBLY
TR−5
1385 Author: Date:
1996 TOYOTA T100 (RM449U)
TRANSFER ASSEMBLY
COMPONENTS

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− TRANSFERTRANSFER ASSEMBLY
1386 Author: Date:
1996 TOYOTA T100 (RM449U)

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TF0629
TF0447
Q09400
FIPG
− TRANSFERTRANSFER ASSEMBLY
TR−7
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE SPEEDOMETER DRIVEN GEAR
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
2. REMOVE TRANSFER INDICATOR SWITCH
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
3. A/T:
REMOVE TRANSFER L4 AND NEUTRAL POSITION
SWITCH
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
HINT:
At the time of installation, check the following items.
Check to see that the input shaft and output shafts rotate
smoothly.
Check to see that shifting can be made smoothly to all
position.
4. A/T:
REMOVE SHIFT GEAR HEAD NO.1 AND NO.2
(a) Using a pin punch and hammer, drive out the 2 slotted
spring pins.
(b) Remove the 2 shift gear heads.
5. REMOVE FRONT RETAINER
(a) Remove the 7 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the bolts.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a plastic hammer, tap the front retainer and remove
it.
HINT:
At the time of installation, please refer to the following items.
Remove any FIPG material and be careful not to drop oil
on the contacting surfaces of the front retainer.
Apply FIPG to the front retainer, as shown.
FIPG:
Part No.08826−00090, THREE BOND 1281,
LOCTITE 242 or equivalent

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TF0614
TF0451
SST
Q06503
SST TR−8
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
6. M/T:
REMOVE CONTROL RETAINER
(a) Remove the 4 bolts, control retainer and gasket.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
HINT:
At the time of installation, install a new gasket.
(b) Remove the select return spring from the retainer.
7. A/T:
REMOVE UPPER COVER AND OIL DEFLECTOR
Remove the 4 bolts, upper cover, 2 gaskets and oil deflector.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
HINT:
At the time of installation, install a new gasket.
8. REMOVE FRONT COMPANION FLANGE
(a) Using a chisel and hammer, loosen the staked part of the
nut.
HINT:
At the time of installation, stake a new lock nut.
(b) Using SST to hold the flange, remove the companion
flange lock nut.
SST 09330−00021
Torque: 118 N·m (1,200 kgf·cm, 87 ft·lbf)
(c) Using SST, remove the companion flange.
SST 09950−40010
9. REMOVE REAR COMPANION FLANGE
Remove the rear companion flange in the same way as the front
companion flange.
HINT:
At the time of installation, please refer to the following items.
Front companion flange bolts are silver.
Rear companion flange bolts are black.