1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine TR01X−02
− TRANSFEROIL PUMP BODY
TR−17
1397 Author: Date:
1996 TOYOTA T100 (RM449U)
OIL PUMP BODY
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR0D0−01
TF0547
TF0485
TR−18
− TRANSFEROIL PUMP BODY
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. CHECK OIL PUMP OPERATION
Install the oil pump drive gear to the drive rotor and check that
the drive rotor turns smoothly.
2. REMOVE STRAIGHT SCREW PLUG, SPRING, BALL
AND SEAT
(a) Using a hexagon wrench, remove the straight screw plug.
Torque: 29 N·m (300 kgf·cm, 22 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
(b) Using a magnetic finger remove the spring and ball.
(c) Using SST, pull out the seat.
SST 09921−00010
(d) Remove the O−ring from the seat.
HINT:
At the time of reassembly, please refer to the following items.
Install a new O−ing to the seat.
When installing the seat, push the seat until it touches the
bottom of the hole in the body.
3. REMOVE OIL PUMP PLATE
(a) Using a torx socket wrench (T30), unscrew the 3 torx
screws.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
(b) Remove the oil pump plate.
4. REMOVE DRIVE ROTOR AND DRIVEN ROTOR
HINT:
At the time of reassembly, apply gear oil to the both rotors.

Downloaded from www.Manualslib.com manuals search engine TR0D1−01
TF0486
TF0487
TF0488
− TRANSFEROIL PUMP BODY
TR−19
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT DRIVEN ROTOR BODY CLEARANCE
(a) Push the driven rotor to one side of the body.
(b) Using a feeler gauge, measure the clearance.
Standard clearance:
0.10 − 0.16 mm (0.0039 − 0.0063 in.)
Maximum clearance: 0.16 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the drive rotor,
driven rotor or pump body.
2. INSPECT BOTH ROTORS TIP CLEARANCE
Using a feeler gauge, measure the clearance between both ro-
tor tips.
Standard clearance:
0.08 − 0.16 mm (0.0031 − 0.0063 in.)
Maximum clearance: 0.16 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the drive rotor,
driven rotor or pump body.
3. INSPECT BOTH ROTORS SIDE CLEARANCE
Using a steel straight edge and feeler gauge, measure the
clearance between the rotors and straight edge.
Standard clearance:
0.03 − 0.08 mm (0.0012 − 0.0031 in.)
Maximum clearance: 0.08 mm (0.0031 in.)
If the clearance exceeds the maximum, replace the drive rotor,
driven rotor or pump body.

Downloaded from www.Manualslib.com manuals search engine TR0D2−01
TR−20
− TRANSFEROIL PUMP BODY
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page TR−18).

Downloaded from www.Manualslib.com manuals search engine TR01Z−02
− TRANSFERDRIVEN SPROCKET
TR−21
1401 Author: Date:
1996 TOYOTA T100 (RM449U)
DRIVEN SPROCKET
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR020−02
TF0512
TF0513
Steel Bar
SST
TF0514
TF0515
TR−22
− TRANSFERDRIVEN SPROCKET
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE FRONT BEARING
Using a press, remove the front bearing.
2. REMOVE REAR BEARING
Using SST, steel bar and a press, remove the rear bearing.
SST 09950−00020
3. INSTALL REAR BEARING
Using a press, install the rear bearing.
4. INSTALL FRONT BEARING
Using a press, install the front bearing.
HINT:
Make sure to install the bearing in the correct direction.

Downloaded from www.Manualslib.com manuals search engine TR021−02
Z19022
A/T:
M/T:High and Low Clutch Sleeve
High and Low Clutch Hub
 Key Retainer High and Low Clutch Hub
High and Low Hub Sleeve
Snap RingShifting Key Spring Snap Ring
Ball
Bearing
Spacer Rear Output Shaft
Shifting Key Spring
Front Drive Clutch Sleeve
Drive SprocketNeedle Roller Bearing
Shifting Key
Synchronizer Ring
 Non−reusable partShifting Key
− TRANSFERREAR OUTPUT SHAFT
TR−23
1403 Author: Date:
1996 TOYOTA T100 (RM449U)
REAR OUTPUT SHAFT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR0D3−01
TF0516
TF0517
TF0549
TF0518
SST
TF0620
TR−24
− TRANSFERREAR OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust clear-
ance.
Standard clearance:
0.10 − 0.25 mm (0.0039 − 0.0098 in.)
Maximum clearance: 0.25 mm (0.0098 in.)
If the clearance exceeds the maximum, replace the drive
sprocket.
2. M/T:
REMOVE HIGH AND LOW HUB SLEEVE
ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the hub sleeve and 3 shifting keys.
(c) Using a press, remove the clutch hub, 2 key springs and
key retainer.
3. A/T:
REMOVE HIGH AND LOW HUB SLEEVE
ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the hub sleeve.
(c) Using a press, remove the clutch hub.
4. REMOVE REAR BEARING, SPACER AND DRIVE
SPROCKET WITH FRONT DRIVE CLUTCH SLEEVE
ASSEMBLY
(a) Using SST and a press, remove the bearing.
SST 09950−00020
(b) Remove these parts:
Spacer and ball
Drive sprocket with front drive hub and hub sleeve
Needle roller bearing
Synchronizer ring