1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine CL029−01
Q02468
SST CL−6
− CLUTCHCLUTCH MASTER CYLINDER
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAW OUT FLUID WITH SYRINGE
2. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
3. REMOVE CLIP AND CLEVIS PIN
4. REMOVE MOUNTING NUTS AND PULL OUT MASTER
CYLINDER
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine CL02D−03
Q07554
3RZ−FE: 5VZ−FE:
Clutch Line
Bleeder Plug
Release
Cylinder BodyClutch LineBleeder PlugPush Rod
Release Cylinder BodyBoot
Piston
Spring
N·m (kgf·cm, ft·lbf) : Specified torque
CL−10
− CLUTCHCLUTCH RELEASE CYLINDER
1245 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH RELEASE CYLINDER
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine CL02E−03
Z17113
SST
Q06733
− CLUTCHCLUTCH RELEASE CYLINDER
CL−11
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-
INDER
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine CL02L−01
Q06647
5VZ−FE 3RZ−FE
SST Flywheel
Side
Q06958
1,4
7
3
62,58 Matchmarks
Q06641
SST
Z00762
Q06642
− CLUTCHCLUTCH UNIT
CL−19
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them and the
clutch cover in position.
SST 09301−00110
(b) Align the matchmarks on the clutch cover and flywheel.
(c) Torque the 6 bolts on the clutch cover in the order shown.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non−alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333−00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to the these parts.
Release fork and hub contact point
Release fork and push rod contact point
Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887−01706 (100g).
4. INSTALL BOOT, RELEASE BEARING AND FORK TO
TRANSMISSION
Install the boot and bearing to the release fork, and then install
them to the transmission.

Downloaded from www.Manualslib.com manuals search engine MT0501
Down
ClothCounterclockwise
MT0ER−01
D10948
MT−4
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION WITH ENGINE (See page
EM−65)
2. REMOVE REAR END PLATE
Remove the 4 bolts, nuts and rear end plate.
Torque:37 N·m (380 kgf·cm, 27 ft·lbf)
3. REMOVE STARTER
Remove the 2 bolts and starter.
Torque:39 N·m (400 kgf·cm, 29 ft·lbf)
4. REMOVE TRANSMISSION FROM ENGINE
(a) Remove the 6 transmission mounting bolts from the en-
gine.
Torque:72 N·m (730 kgf·cm, 53 ft·lbf)
(b) Pull out the transmission toward the rear.
5. REMOVE ENGINE REAR MOUNTING
(a) Remove the 4 bolts and engine rear mounting.
Torque:25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Lower the front side of the transmission and remove it
from the front side of the vehicle.

Downloaded from www.Manualslib.com manuals search engine MT0501
Down
ClothCounterclockwise
MT04O−02
Q06817
Installation
Front
Select Return Spring
Tip of Shift Lever
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
MT−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION SHIFT LEVER
(a) Remove the 4 screws and front console box.
(b) Remove the 4 screws and shift lever boot retainer.
(c) Cover the shift lever cap with a cloth.
(d) Then, pressing down on the shift lever cap, rotate it coun-
terclockwise to remove.
(e) Pull out the shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of the shift lever.
2. REMOVE TRANSFER SHIFT LEVER
Using snap ring pliers, remove the snap ring and pull out the
shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of shift lever.
3. RAISE VEHICLE AND DRAIN TRANSMISSION OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 2.2 liters (2.3 US qts, 1.9 Imp. qts)
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE FRONT AND REAR PROPELLER SHAFTS
(See page PR−10)
5. DISCONNECT SPEEDOMETER CABLE
6. DISCONNECT BACK−UP LIGHT SWITCH AND 4WD
INDICATOR SWITCH CONNECTORS
7. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
Remove the 4 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Q06824
Q06823
Q06822
Q10111
MT−8
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
1996 TOYOTA T100 (RM449U)
8. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 nuts, gasket and oxygen sensor.
(b) Remove the 2 bolts, retainer and gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(c) Remove the 3 bolts and bracket.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
(d) Remove the 3 nuts, front exhaust pipe and 2 gaskets.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
9. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
10. RE MO V E STIFFE NE R PLATE (RH AND LH) AND
REAR END PLATE
Remove the 8 bolts, stiffener plate (RH and LH) and rear end
plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
11. REMOVE STABILIZER BAR (See page SA−126)
12. JACK UP TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.
13. REMOVE CROSSMEMBER
(a) Remove the 4 set bolts of the engine rear mounting.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Remove the 8 bolts and crossmember.
Torque: 95 N·m (970 kgf·cm, 70 ft·lbf)
14. REMOVE TRANSMISSION WITH TRANSFER
(a) Remove the 6 transmission mounting bolts from the en-
gine.
Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
(b) Disconnect the 3 wire clamps from the transmission.
(c) Pull out the transmission with the transfer down and to-
ward the rear.
15. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Q06907
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
MT−9
1996 TOYOTA T100 (RM449U)
16. REMOVE TRANSFER FROM TRANSMISSION
(a) Remove the transfer adaptor rear mounting bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) Pull the transfer straight up and remove it from the trans-
mission.
HINT:
Take care not to damage the adaptor rear oil seal with the trans-
fer input gear spline.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the adaptor oil seal and shift the 2 shift fork
shafts to the high − 4 position.