1996 TOYOTA T100 manual transmission

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Q00880
3rd
2nd 1st
D00873
3rd
2nd
1st
Q00859
WM0053
MT−22
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of each
gear.
Standard clearance:
0.10 − 0.25 mm (0.0039 − 0.0098 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
2. INSPECT EACH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of each
gear.
Standard clearance:
1st and 2nd gears:
0.009 − 0.060 mm (0.0004 − 0.0024 in.)
3rd gear:
0.015 − 0.066 mm (0.0006 − 0.0026 in.)
Maximum clearance:
1st and 2nd gears:
0.150 mm (0.0059 in.)
3rd gear:
0.200 mm (0.0079 in.)
If the clearance exceeds the maximum, replace the gear, shaft
or needle roller bearing.
3. REMOVE OUTPUT SHAFT CENTER BEARING AND
1ST GEAR ASSEMBLY
(a) Shift the No.1 hub sleeve onto the 2nd gear.
(b) Using a press, remove the center bearing, 1st gear,
needle roller bearing, inner race and synchronizer ring.
4. REMOVE LOCKING BALL ON OUTPUT SHAFT
Using a magnetic finger, remove the locking ball.
5. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 2ND GEAR
AND NEEDLE ROLLER BEARING
Using a press, remove the parts from the shaft as an assembly.

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WM0055
Q00888
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−23
1996 TOYOTA T100 (RM449U)
6. REMOVE NO.1 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO. 1 CLUTCH HUB
(a) Remove the No.1 hub sleeve from the No.1 clutch hub.
(b) Push the shifting key spring with a screwdriver, remove
the 3 shifting keys and key springs.
7. REMOVE NO.2 HUB SLEEVE ASSEMBLY AND 3RD
GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the No.2 hub sleeve, synchronizer
ring and 3rd gear.
8. REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND
SPRING FROM NO.2 CLUTCH HUB
(a) Remove the No.2 hub sleeve from the No.2 clutch hub.
(b) Push the shifting key spring with a screwdriver, remove
the 3 shifting keys and key springs.

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MT03U−01
WM0065
Q00930
MT0780
MT−24
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT 1ST GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) 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 the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.5 mm (0.020 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. INSPECT 2ND AND 3RD GEAR SYNCHRONIZER
RINGS
(a) Check for wear or damage.
(b) Install the synchronizer inner ring, middle ring and outer
ring to each gear.
(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.

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WM0066
Q00860
Q00861
Q00862
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−25
1996 TOYOTA T100 (RM449U)
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and the gear spline end.
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
3. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeves and shift forks.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
4. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using vernier calipers, measure the output shaft flange
thickness.
Minimum thickness: 5.60 mm (0.2205 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using vernier calipers, measure the inner race flange
thickness.
Minimum thickness: 4.78 mm (0.1881 in.)
If the thickness is less than the minimum, replace the inner race.
(c) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
2nd gear: 42.975 mm (1.6919 in.)
3rd gear: 31.969 mm (1.2586 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.

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MT−26
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
(d) Using a micrometer, measure the outer diameter of the in-
ner race.
Minimum diameter: 42.975 mm (1.6919 in.)
If the outer diameter is less than the minimum, replace the inner
race.
(e) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)
If the runout exceeds the maximum, replace the output shaft.

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Q00888
Z02648
No.2 No.1
Front Front
Q00865
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−27
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 AND NO.2 CLUTCH HUBS INTO HUB
SLEEVE
(a) Install the 3 shifting key springs to the clutch hub.
(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 to
the hub sleeve, as shown.
2. INSTALL 3RD GEAR AND NO.2 CLUTCH HUB ON
OUTPUT SHAFT
(a) Apply gear oil to the shaft.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.

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Q00866
WM0119
MT−28
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
(c) Using a press, install the 3rd gear and No.2 clutch hub.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
C−11.75 − 1.80 (0.0689 − 0.0709)
D1.80 − 1.85 (0.0709 − 0.0728)
111.86 − 1.91 (0.0732 − 0.0752)
121.92 − 1.97 (0.0756 − 0.0776)
131.98 − 2.03 (0.0780 − 0.0799)
142.04 − 2.09 (0.0803 − 0.0823)
152.10 − 2.15 (0.0827 − 0.0846)
(b) Using a snap ring expander, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MT−21)
5. INSTALL 2ND GEAR AND NO.1 CLUTCH HUB
(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 2nd gear.
(d) Using a press, install the 2nd gear and No.1 clutch hub.
6. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MT−21)

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WM0122
SST
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−29
1996 TOYOTA T100 (RM449U)
7. INSTALL LOCKING BALL AND 1ST GEAR ASSEMBLY
(a) Install the locking ball in the shaft.
(b) Apply gear oil to the bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller
bearing and bearing inner race.
(d) Install the assembly on the output shaft with the synchro-
nizer ring slots aligned with the shifting keys and turn the
inner race to align it with the locking ball.
8. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a press, install the bearing on the output shaft
with the outer race snap ring groove toward the rear.
SST 09506−35010
HINT:
Hold the 1st gear inner race to prevent it from falling.
9. INSPECT 1ST GEAR THRUST CLEARANCE
(See page MT−21)