1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine MT04R−01
Q06902
FIPG
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−13
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE BACK−UP LIGHT SWITCH
Torque: 44 N·m (450 kgf·cm, 32 ft·lbf)
2. 2WD:
REMOVE SPEEDOMETER DRIVEN GEAR
Remove the driven gear lock plate set bolt and driven gear.
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
3. REMOVE CLUTCH HOUSING FROM TRANSMISSION
CASE
Remove the 9 bolts and clutch housing from the transmission
case.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
4. REMOVE CONTROL SHIFT LEVER RETAINER
(a) Remove the 6 (2WD) or 4 (4WD) bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the retainer and gasket (2WD) or oil deflector
(4WD).
5. REMOVE 2 RESTRICT PINS
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
6. 2WD:
REMOVE EXTENSION HOUSING
(a) Remove the shift lever housing set bolt.
Torque: 38 N·m (390 kgf·cm, 28 ft·lbf)
(b) Remove the 10 bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(c) Using a plastic hammer, tap the extension housing, re-
move the shift lever housing and shift and select lever.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or
equivalent

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FIPG
Q06900
FIPG
x8
Q06903
FIPG
MT−14
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
7. 4WD:
REMOVE TRANSFER ADAPTOR
(a) Remove the shift lever housing set bolt.
Torque: 38 N·m (390 kgf·cm, 28 ft·lbf)
(b) Remove the 10 bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(c) Using a plastic hammer, tap the transfer adaptor, remove
the shift lever housing and the shift and select lever.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or
equivalent
8. REMOVE FRONT BEARING RETAINER
(a) Remove the 8 bolts.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 17 N·m (170 kgf·cm, 12 ft·lbf)
(b) Using a plastic hammer, tap the front bearing retainer.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or
equivalent
9. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
10. SEPARATE INTERMEDIATE PLATE FROM TRANS-
MISSION CASE
(a) Using a brass bar and hammer, carefully tap the transmis-
sion case.
(b) Remove the transmission case from the intermediate
plate.
HINT:
At the time of reassembly, please refer to the following item.
Align the each bearing outer race, each fork shaft end and re-
verse idler gear shaft end with the case installation holes.

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Q06905
Q06764
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−15
1996 TOYOTA T100 (RM449U)
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or
equivalent
11. REMOVE MAGNET FROM INTERMEDIATE PLATE
12. MOUNT INTERMEDIATE PLATE IN VISE
(a) Use the 2 clutch housing bolts, plate washers and suit-
able nuts, as shown.
HINT:
Increase or decrease plate washers so that the bolt tip does not
protrude from the nut.
(b) Mount the intermediate plate in a vise.
13. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench, remove the 4 plugs.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(b) Using a magnetic finger, remove the 3 springs and balls.
14. REMOVE SHIFT FORK SET BOLT
Remove the 2 bolts from the shift forks No.1 and No.2.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
15. REMOVE SLOTTED SPRING PIN
Using a pin punch and hammer, drive out the pin from the shift
fork No.3.
16. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the 4 snap rings
from each shift fork shaft.

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RM0072
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−17
1996 TOYOTA T100 (RM449U)
22. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and reverse shift arm bracket.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
23. 2WD:
REMOVE SPEEDOMETER DRIVE GEAR
(a) Using 2 screwdrivers and a hammer, tap out the rear snap
ring, and remove the drive gear and ball.
(b) Using 2 screwdrivers and a hammer, tap out the front
snap ring, and remove the drive gear.
24. REMOVE OUTPUT SHAFT REAR BEARING
(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.)
A2.65 − 2.70 (0.1043 − 0.1063)
B2.70 − 2.75 (0.1063 − 0.1083)
C2.75 − 2.80 (0.1083 − 0.1102)
D2.80 − 2.85 (0.1102 − 0.1122)
E2.85 − 2.90 (0.1122 − 0.1142)
F2.90 − 2.95 (0.1142 − 0.1161)
G2.95 − 3.00 (0.1161 − 0.1181)
H3.00 − 3.05 (0.1181 − 0.1201)
J3.05 − 3.10 (0.1201 − 0.1220)
K3.10 − 3.15 (0.1220 − 0.1240)
L3.15 − 3.20 (0.1240 − 0.1260)
M3.20 − 3.25 (0.1260 − 0.1280)
N3.25 − 3.30 (0.1280 − 0.1299)
P3.30 − 3.35 (0.1299 − 0.1319)
Q3.35 − 3.40 (0.1319 − 0.1339)
R3.40 − 3.45 (0.1339 − 0.1358)
S3.45 − 3.50 (0.1358 − 0.1378)

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)

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Q04410
Z03582
Q07365
SST
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
MT−43
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Remove the reverse restrict pin.
(1) Using a torx socket wrench (T40), remove the screw
plug.
(2) Using a pin punch and hammer, drive out the slotted
spring pin.
(3) Remove the reverse restrict pin.
(b) Inspect the reverse restrict pin.
Turn and push the reverse restrict pin by hand.
Check for smooth operation.
(c) Install the reverse restrict pin.
(1) Install the reverse restrict pin to the extension hous-
ing or transfer adaptor.
(2) Using a pin punch and hammer, drive in the slotted
spring pin, as shown.
(3) Apply sealant to the plug threads.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(4) Using a torx socket wrench (T40), install and torque
the screw plug.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
2. 2WD:
IF NECESSARY, REPLACE EXTENSION HOUSING
OIL SEAL
(a) Remove the dust deflector.
(b) Using a screwdriver, pry out the oil seal.
(c) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00570), 09950−70010
(09951−07150)
Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(d) Install the deflector.

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D10954
D10955
MT−4
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION UNIT
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION WITH ENGINE (See page
EM−65)
2. REMOVE REAR END PLATE
Remove the 4 bolts, 2 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 3 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.
HINT:
At the time of installation, please refer to the following item.
Align the input shaft spline with the clutch disc and install the
transmission to the engine.
5. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

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Q06713
Q06714
FIPG
Q06715
FIPG
x 7 MT−8
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE BACK−UP LIGHT SWITCH
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
2. REMOVE SPEEDOMETER DRIVEN GEAR
Remove the lock plate set bolt and driven gear.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
3. REMOVE CLUTCH HOUSING FROM TRANSMISSION
CASE
Remove the 9 bolts and clutch housing.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE CONTROL SHIFT LEVER RETAINER
(a) Remove the 6 bolts.
Sealant:
Part No.08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the control shift lever retainer and oil baffle plate.
5. REMOVE 2 RESTRICT PINS AND GASKETS
HINT:
At the time of reassembly, please refer to the following item.
Install the black pin on the reverse gear/5th gear side.
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
6. REMOVE EXTENSION HOUSING
(a) Remove the shift lever housing set bolt.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Remove the 9 bolts from the extension housing.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(c) Using a plastic hammer, carefully tap the extension hous-
ing.
(d) Disengage the shift and select lever from the shift head.
(e) Pull out the extension housing.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or equiva-
lent
7. REMOVE FRONT BEARING RETAINER AND BEAR-
ING SNAP RING
(a) Remove the 7 bolts.
Sealant:
Part No.08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Remove the front bearing retainer.