1996 TOYOTA T100 engine

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F02979
FIPG
TF0454
TF0455
Z14087
FIPG
− TRANSFERTRANSFER ASSEMBLY
TR−9
1996 TOYOTA T100 (RM449U)
10. REMOVE EXTENSION HOUSING
(a) Remove the 5 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 extension housing 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 extension housing.
Apply FIPG to the extension housing, as shown.
FIPG:
Part No.08826−00090,
THREE BOND 1281 or equivalent
11. REMOVE SPEEDOMETER DRIVE GEAR
(a) Remove the speedometer drive gear.
HINT:
At the time of installation, please refer to the following item.
Make sure to install the speedometer drive gear in the correct
direction.
(b) Using a magnetic finger, remove the ball from the rear out-
put shaft.
12. SEPARATE FRONT CASE AND REAR CASE
(a) Remove the 12 bolts.
Torque: 28 N·m (285 kgf·cm, 20 ft·lbf)
(b) Using a plastic hammer, tap the rear case and separate
the front case and rear case.
HINT:
At the time of installation, please refer to the following items.
Shift the high and low clutch sleeve to low side (rear side)
and assemble the front case and rear case.
Remove any FIPG material and be careful not to drop oil
on the contacting surfaces of the rear case.
Apply FIPG to the rear case, as shown.
FIPG:
Part No.08826−00090,
THREE BOND 1281 or equivalent

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TF0458
TF0459
TF0619F03415
M/T:
A/T: TR−10
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
13. REMOVE STRAIGHT SCREW PLUGS, SPRINGS AND
LOCKING BALLS
(a) Using a hexagon wrench, remove the 2 straight screw
plugs.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the plugs.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a magnetic finger, remove the spring and ball from
the both holes.
14. REMOVE FRONT DRIVE FORK SHAFT, FORK,
SPRING AND STOPPER
(a) Using a pin punch and hammer, drive out the 2 slotted
spring pins.
HINT:
When the pin is removed from the front drive fork shaft, the shaft
will spring loose if the pin punch is removed, so keep the pin
punch inserted in the shaft hole.

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TF0622F03416
M/T:
A/T:
TF0460
− TRANSFERTRANSFER ASSEMBLY
TR−11
1996 TOYOTA T100 (RM449U)
HINT:
At the time of installation, please refer to the following item.
When installing the pin in the front drive fork shaft, push the
shaft towards the rear case and install the pin while the spring
is compressed.
(b) Hold the front drive fork shaft in place by hand, when re-
moving the pin punch.
(c) Remove the front drive fork shaft, spring and fork.
HINT:
At the time of installation, please refer to the following items.
Place the front drive shift fork into the groove of the clutch
sleeve.
Make sure to install the shift fork and stopper in the correct
direction.

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TF0464
TF0465
TR−12
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
(d) Using a magnetic finger, remove the straight pin.
HINT:
At the time of installation, please refer to the following item.
Apply gear oil to the straight pin and insert it into the case hole.
15. REMOVE HIGH AND LOW FORK SHAFT, SHIFT FORK
AND STOPPER
HINT:
At the time of installation, please refer to the following items.
Place the high and low shift fork into the groove of the
clutch sleeve.
Make sure to install the shift fork in the correct direction.
16. REMOVE REAR OUTPUT SHAFT, DRIVEN
SPROCKET AND CHAIN
(a) Using a snap ring expander, remove the snap ring.
(b) Mount the rear case in the vise.
NOTICE:
Be careful not to damage the sealing surface.
(c) Using a plastic hammer, tap the rear case with pulling the
rear output shaft and driven sprocket.
HINT:
At the time of installation, please refer to the following item.
If necessary, heat the rear case to about 70°C (158°F).
(d) Remove the chain.

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TF0467
TF0468
TF0470
TF0471
− TRANSFERTRANSFER ASSEMBLY
TR−13
1996 TOYOTA T100 (RM449U)
17. M/T:
REMOVE SYNCHRONIZER RING FROM INPUT
SHAFT
HINT:
At the time of installation, please refer to the following items.
Apply gear oil to the synchronizer ring.
Align the synchronizer ring slots with the shifting keys,
and install it on the high and low clutch hub.
18. REMOVE SEPARATOR WITH OIL STRAINER
(a) Remove the 3 bolts and the separator with the oil strainer.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the O−ring from the oil strainer pipe.
HINT:
At the time of installation, please refer to the following item.
Coat a new O−ring with gear oil and install it to the oil strainer
pipe.
19. REMOVE OIL PUMP BODY ASSEMBLY
Remove the 3 bolts and the oil pump body assembly.
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
20. REMOVE OIL PUMP DRIVE GEAR
21. REMOVE PLANETARY GEAR ASSEMBLY WITH
INPUT SHAFT
(a) Using a snap ring expander, remove the snap ring.
(b) Pull out the planetary gear assembly with the input shaft.
HINT:
At the time of installation, please refer to the following item.
If necessary, heat the front case to about 70°C (158°F).

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TF0474
TR−14
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
22. REMOVE LOW GEAR SPLINE PIECE
(a) Using a screwdriver, remove the snap ring.
HINT:
At the time of installation, please refer to the following item.
Be sure the end gap of the snap ring is not aligned with cutout
portion of the planetary carrier.
(b) Remove the low gear spline piece.
23. REMOVE NEEDLE ROLLER BEARING FROM INPUT
SHAFT
HINT:
At the time of installation, apply gear oil to the needle roller bear-
ing.
24. REMOVE INPUT SHAFT STOPPER AND THRUST
BEARING
(a) Using a snap ring expander, remove the snap ring.
HINT:
At the time of installation, please refer to the following item.
Select a snap ring that will allow 0.05 − 0.15 mm (0.0020 −
0.0059 in.) 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)
H2.45 − 2.50 (0.0965 − 0.0984)
J2.50 − 2.55 (0.0984 − 0.1004)
K2.55 − 2.60 (0.1004 − 0.1024)
L2.60 − 2.65 (0.1024 − 0.1043)
M2.65 − 2.70 (0.1043 − 0.1063)
N2.70 − 2.75 (0.1063 − 0.1083)
P2.75 − 2.80 (0.1083 − 0.1102)
Q2.80 − 2.85 (0.1102 − 0.1122)
R2.85 − 2.90 (0.1122 − 0.1142)
S2.90 − 2.95 (0.1142 − 0.1161)
T2.95 − 3.00 (0.1161 − 0.1181)
U3.00 − 3.05 (0.1181 − 0.1201)

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TF0478
TF0479
TF0507
− TRANSFERTRANSFER ASSEMBLY
TR−15
1996 TOYOTA T100 (RM449U)
(b) Remove the input gear stopper, thrust bearing, race and
the 2 pins.
HINT:
At the time of installation, apply gear oil to the thrust bearing and
race.
25. REMOVE INPUT SHAFT, THRUST BEARING AND
RACE
26. REMOVE PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring.
HINT:
At the time of installation, please refer to the following item.
Be sure the end gap of the snap ring is not aligned with the up-
per side of the case.
(b) Remove the plug, spring and pin.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the plug.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Remove the planetary ring gear.
HINT:
At the time of installation, make sure to install the ring gear in
the correct direction.

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TR−16
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page TR−7).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before assembly.