1996 TOYOTA T100 manual transmission

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.

Downloaded from www.Manualslib.com manuals search engine MT052−01
Z03569
Q06689
Q06831
Q06832
MT−36
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Install the spacer, counter 5th gear and needle roller bear-
ings.
(b) Using a dial indicator, measure the counter 5th gear radial
clearance.
Standard clearance:
0.015 − 0.068 mm (0.0006 − 0.0027 in.)
Maximum clearance:
0.160 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the gear bear-
ing or shaft.
2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter
gear journal.
Minimum diameter: 27.860 mm (1.0968 in.)
If the outer diameter is less than the minimum, replace the
counter gear.
3. INSPECT 5TH SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer pull ring, cone ring and outer ring
to the gear spline piece No.5.
(c) 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 it does not lock, replace the synchronizer ring.

Downloaded from www.Manualslib.com manuals search engine WM0066
Q01803
Q06775
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
MT−37
1996 TOYOTA T100 (RM449U)
4. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
5. INSPECT REVERSE IDLER GEAR RADIAL CLEAR-
ANCE
Using a dial indicator, measure the reverse idler gear radial
clearance.
Standard clearance:
0.040 − 0.082 mm (0.0016 − 0.0032 in.)
Maximum clearance:
0.130 mm (0.0051 in.)
If the clearance exceeds the maximum, replace the reverse
idler gear or reverse idler gear shaft.
6. INSPECT REVERSE IDLER GEAR AND SHIFT ARM
CLEARANCE
Using a feeler gauge, measure the clearance between the re-
verse idler gear and shift arm.
Standard clearance:
0.05 − 0.35 mm (0.0020 − 0.0138 in.)
Maximum clearance:
0.50 mm (0.0197 in.)
If the clearance exceeds the maximum, replace the shift arm or
reverse idler gear.

Downloaded from www.Manualslib.com manuals search engine MT053−01
Z03575
SST
RM0013
Socket Wrench
Z03576
MT−38
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE COUNTER GEAR FRONT
BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the bearing.
SST 09950−00020
(c) Replace the side race.
(d) Using a socket wrench and press, install a new bearing
and side race.
(e) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.00 − 2.05 (0.0787 − 0.0807)
B2.05 − 2.10 (0.0807 − 0.0827)
C2.10 − 2.15 (0.0827 − 0.0846)
D2.15 − 2.20 (0.0846 − 0.0866)
E2.20 − 2.25 (0.0866 − 0.0886)
F2.25 − 2.30 (0.0886 − 0.0906)
(f) Using a snap ring expander, install the snap ring.

Downloaded from www.Manualslib.com manuals search engine MT054−01
Q06830
Q06828
Q07460
Q06819
Front
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
MT−39
1996 TOYOTA T100 (RM449U)
REASSEMBLY
INSTALL SYNCHRONIZER RING ASSEMBLY TO HUB
SLEEVE NO.3
(a) Put the key spring to the hole of the shifting key.
(b) Push the 3 shifting keys with the 3 key springs to the re-
verse synchronizer ring.
(c) Install the synchronizer cone ring to the reverse synchro-
nizer pull ring and turn the pull ring.
(d) Install the 5th synchronizer ring.
(e) Install the reverse synchronizer ring.
(f) Turn the reverse synchronizer pull ring.
(g) While pushing the 3 shifting keys, install the synchronizer
ring assembly to the hub sleeve No.3.

Downloaded from www.Manualslib.com manuals search engine MT055−01
RM0322 Non−reusable partFront Bearing Retainer Oil Seal MT−40
− MANUAL TRANSMISSION (R150, R150F)FRONT BEARING RETAINER OIL SEAL
1295 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BEARING RETAINER OIL SEAL
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine MT056−01
Z03583
Q07394
SST
− MANUAL TRANSMISSION (R150, R150F)FRONT BEARING RETAINER OIL SEAL
MT−41
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE FRONT BEARING RETAINER
OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00510), 09950−70010
(09951−07150)
Drive in depth:
11.7 ± 0.5 mm (0.461 ± 0.020 in.) from retainer end

Downloaded from www.Manualslib.com manuals search engine MT058−04
Z16044
4WD:
Slotted Spring PinTransfer Adaptor
 Oil Seal
 O−Ring
Dust Deflector
 Oil Seal 2WD: Oil Receiver Reverse Restrict Pin
Oil Receiver PipeOil Receiver Reverse Restrict Pin
Extension Housing
 Non−reusable part
 Precoated partSlotted Spring PinSpeedometer Driven Gear
Plug

Plug

Plug MT−42
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
1297 Author: Date:
1996 TOYOTA T100 (RM449U)
EXTENSION HOUSING AND TRANSFER ADAPTOR
COMPONENTS