1996 TOYOTA T100 key

Downloaded from www.Manualslib.com manuals search engine Z15461
Output Shaft Assembly
Speedometer Drive Gear
Snap Ring Ball Bearing
Spacer
 Bearing Input Shaft
Synchronizer Ring
Rear Bearing Retainer
Gear Spline Piece No.5
Synchronizer Cone Ring
Hub Sleeve No.3 Reverse Idler Gear
Shifting Key SpringShaft
BallShifting Key
Counter 5th Gear
Reverse Synchronizer
Pull Ring
5th Synchronizer Ring
Reverse Synchronizer Ring Thrust Washer
Counter Gear Rear Bearing
Shift Fork Shaft No.2Needle Roller Bearing
Straight Pin Intermediate Plate
Counter Gear
 Front Bearing
Interlock Pin
Straight Pin
Shift Fork Shaft No.1
Slotted Spring Pin
Shift Fork No.3
2WD: 2WD:
Shift Fork No.1 Reverse Idler GearMagnet
Shift Fork Shaft No.3Shift Lever Housing
Shift and Select Lever
Shift Lever Housing
Shift and Select Lever4WD:
 Reverse Shift Arm Bracket
Reverse Shift Arm
E−Ring Reverse Shift Fork Shift Fork Shaft
No.4
 Non−reusable part
 Precoated part Bearing
Snap Ring
Snap Ring Snap RingSnap Ring
Snap Ring
Snap Ring
Snap Ring
 
Spring
Shift Fork No.2


Interlock Pin Snap Ring
Interlock Pin Snap Ring
Snap Ring
MT−12
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1267 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine Q06688
Q06605
SST
RM0024
SST
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−19
1996 TOYOTA T100 (RM449U)
27. REMOVE GEAR SPLINE PIECE NO.5, SYNCHRONIZ-
ER RING, NEEDLE ROLLER BEARING AND COUNT-
ER 5TH GEAR WITH HUB SLEEVE NO.3
(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.)
A2.80 − 2.85 (0.1102 − 0.1122)
B2.85 − 2.90 (0.1122 − 0.1142)
C2.90 − 2.95 (0.1142 − 0.1161)
D2.95 − 3.00 (0.1161 − 0.1181)
E3.00 − 3.05 (0.1181 − 0.1201)
F3.05 − 3.10 (0.1201 − 0.1220)
G3.10 − 3.15 (0.1220 − 0.1240)
(b) Using SST, remove the gear spline piece No.5.
SST 09950−50010
(c) Remove the counter 5th gear with the hub sleeve No.3.
HINT:
At the time of reassembly, please refer to the following items.
Using SST and a hammer, drive in the gear spline piece
No.5 with the synchronizer ring slots aligned with the shift-
ing keys.
SST 09316−60011 (09316−00011)
When installing the gear spline piece No.5, support the
counter gear in front with a 1.4 − 2.3 kg (3 − 5 lb) hammer
or equivalent.
28. REMOVE THRUST WASHER AND BALL FROM
COUNTER GEAR
29. REMOVE REAR BEARING RETAINER
Remove the 4 bolts and rear bearing retainer.
HINT:
At the time of reassembly, please refer to the following item.
Align the rear bearing retainer to the reverse idler gear shaft
groove.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

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 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)

Downloaded from www.Manualslib.com manuals search engine MT050−01
Z15462
Snap RingCounter Gear
Reverse Idler Gear Shaft
 Counter Gear Front Bearing
Reverse Idler GearGear Spline Piece No.5
Synchronizer Cone Ring
Hub Sleeve No.3
Counter 5th Gear
Needle Roller Bearing
Straight Pin
Thrust Washer
Counter Gear Rear Bearing
 Non−reusable partReverse Synchronizer RingShifting Key Shifting Key Spring5th Synchronizer Ring Reverse Synchronizer Pull RingSnap Ring MT−34
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1289 Author: Date:
1996 TOYOTA T100 (RM449U)
COUNTER GEAR AND REVERSE IDLER GEAR
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine MT051−01
Q07459
Q06828
Q06829
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
MT−35
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
REMOVE HUB SLEEVE NO.3, SHIFTING KEY AND SPRING
FROM SYNCHRONIZER RING
(a) Remove the synchronizer ring assembly from the hub
sleeve No.3.
(b) Turn the reverse synchronizer pull ring.
(c) Remove the reverse synchronizer ring and 5th synchro-
nizer ring from the synchronizer pull ring and cone ring.
(d) Turn the reverse synchronizer pull ring, separate the pull
ring and cone ring.
(e) Push the shifting key and spring, and remove the 3 shift-
ing keys and springs to the reverse synchronizer ring.