1996 TOYOTA T100 key

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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.

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MT−2
− MANUAL TRANSMISSION (W59)TROUBLESHOOTING
1301 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
1. Oil (Level low)
2. Oil (Wrong)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−4
MT−4
MT−6
MT−6
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MT−4
MT−6
MT−6
MT−6
Hard to shift or will not shift
1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)MT−18
MT−21
MT−30
MT−18
MT−21
MT−30
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−6
MT−6
MT−6
MT−6

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Z07227
Shifting Key SpringSynchronizer Outer RingSynchronizer Inner Ring
No.2 Clutch Hub
Lock Ball
No.2 Hub Sleeve
Snap Ring
Needle Roller Bearing
2nd GearSynchronizer Middle RingNo.1 Clutch HUbNeedle Roller BearingOutput Shaft
Shifting Key Shifting Key SpringNo.1 Hub SleeveSynchronizer Ring
Non−reusable part 3rd Gear
Bearing
Inner Race
1st Gear Shifting Key
Synchronizer Middle Ring
Synchronizer Outer Ring
Synchronizer Inner Ring Needle Roller Bearing
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−21
1320 Author: Date:
1996 TOYOTA T100 (RM449U)
OUTPUT SHAFT
COMPONENTS

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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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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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Q00887
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)

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Z15652
Shaft Stopper
Reverse Idler Gear Shaft
Reverse Idler ShaftSnap Ring
Race
Counter Gear
Counter 5th Gear
Reverse Synchronizer
Pull Ring
Shifting Key Spring
No.3 Clutch Hub
Reverse Synchronizer Ring No.3 Hub Sleeve5th Synchronizer RingSynchronizer Cone BearingNeedle Roller Bearing Shifting Key
Spacer
Non−reusable part Snap RingSnap Ring Snap Ring
Bearing 
Bearing 
Spacer Snap Ring Race
Bearing  MT−30
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
1329 Author: Date:
1996 TOYOTA T100 (RM449U)
COUNTER GEAR AND REVERSE IDLER GEAR
COMPONENTS