1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine Q06716FIPG
Q03881
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−9
1996 TOYOTA T100 (RM449U)
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or equiva-
lent
(c) Using a snap ring expander, remove the 2 bearing snap
rings.
8. SEPARATE INTERMEDIATE PLATE FROM TRANS-
MISSION CASE
(a) Using a plastic hammer, carefully tap the transmission
case.
(b) Pull the transmission case from the intermediate plate.
NOTICE:
At the time of reassembly, please refer to the following
item.
Align each bearing outer race and each shift fork shaft end
with the case holes.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or equiva-
lent
9. MOUNT INTERMEDIATE PLATE IN VISE
(a) Use the 2 long clutch housing bolts, plate washers and
suitable 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.
10. REMOVE OIL SEPARATOR
Remove the 2 bolts and oil separator.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
11. REMOVE FRONT MAGNET

Downloaded from www.Manualslib.com manuals search engine Q06267
Short
Middle
Long
Q06717
D00861
D00862
D10957
MT−10
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
12. REMOVE LOCKING BALL AND SPRING
(a) Using a hexagon wrench, remove the 4 straight screw
plugs.
Sealant:
Part No.08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the 3 springs and balls.
13. REMOVE SHIFT FORK, SHIFT FORK SHAFT AND RE-
VERSE IDLER GEAR
(a) Remove the No.1 and No.2 shift fork set bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Remove the bolt and reverse idler gear shaft stopper.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Remove the reverse idler gear and shaft with the snap
ring.
(d) Remove the No.1 shift fork and shaft.
(e) Using a magnetic finger, remove the No.1 and No.2 inter-
lock pins.
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the No.1 and No.2 interlock pins.
(f) Using 2 screwdrivers and a hammer, tap out the No. 2 shift
fork shaft snap ring.
(g) Remove the No. 2 shift fork and shaft.
(h) Using a magnetic finger, remove the No. 3 interlock pin.
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the No.3 interlock pin.
(i) Using a pin punch and hammer, drive out the No. 3 shift
fork pin.
(j) Using a hexagon wrench, remove the plug.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(k) Using a magnetic finger, remove the spring and ball.

Downloaded from www.Manualslib.com manuals search engine D00868
Q05168
SST
D00870
SST
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−15
1996 TOYOTA T100 (RM449U)
20. REMOVE REVERSE GEAR
(a) Using a snap ring expander, remove 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.)
52.25 − 2.30 (0.0886 − 0.0906)
112.30 − 2.35 (0.0906 − 0.0925)
122.35 − 2.40 (0.0925 − 0.0945)
132.40 − 2.45 (0.0945 − 0.0965)
142.45 − 2.50 (0.0965 − 0.0984)
152.50 − 2.55 (0.0984 − 0.1004)
162.55 − 2.60 (0.1004 − 0.1024)
172.61 − 2.66 (0.1028 − 0.1047)
182.67 − 2.72 (0.1051 − 0.1071)
192.73 − 2.78 (0.1075 − 0.1094)
202.79 − 2.84 (0.1098 − 0.1118)
212.85 − 2.90 (0.1122 − 0.1142)
222.91 − 2.96 (0.1146 − 0.1165)
232.97 − 3.02 (0.1169 − 0.1189)
(b) Using SST, remove the reverse gear.
SST 09950−40010
HINT:
At the time of reassembly, please refer to the following item.
Using SST, install the reverse gear.
SST 09312−20011 (09313−00030, 09313−00040,
09313−00050)
21. REMOVE REAR BEARING RETAINER
(a) Using a torx socket wrench (T40), unscrew the 4 torx
screws and remove the rear bearing retainer.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine MT044−01
Q04410
D00877
Reverse Restrict PinSlotted
Spring Pin
WM0085
Q07553
SST
− MANUAL TRANSMISSION (W59)EXTENSION HOUSING
MT−41
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Remove the reverse restrict pin.
(1) Using a hexagon wrench, remove the screw plug.
(2) Using a pin punch and hammer, drive out the slotted
spring pin.
(3) Pull off the lever housing and slide out the shaft.
(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 lever housing.
(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) Install and torque the screw plug.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
2. IF NECESSARY, REPLACE REAR BEARING OUTER
RACE
(a) Using 2 screwdrivers, remove the snap ring.
(b) Using SST, remove the outer race.
SST 09308−00010

Downloaded from www.Manualslib.com manuals search engine AT – AUTOMATIC TRANSMISSION

AUTOMATIC TRANSMISSION SYSTEM AT-1
EXTENSION HOUSING OIL SEAL
(A340E) AT-3
SENSOR ROTOR (A340E) AT-4
SPEEDOMETER DRIVEN GEAR AT-8
VEHICLE SPEED SENSOR AT-10
PARK/NEUTRAL POSITION (PNP)
SWITCH AT-11
VALVE BODY ASSEMBLY AT-12
PARKING LOCK PAWL AT-17
THROTTLE CABLE AT-18
SHIFT LOCK SYSTEM AT-19
AUTOMATIC TRANSMISSION UNIT
(A340E) AT-26
AUTOMATIC TRANSMISSION UNIT
(A340F) AT-33
TORQUE CONVERTER CLUTCH AND
DRIVE PLATE AT-38

Downloaded from www.Manualslib.com manuals search engine D00779
5VZ−FE
D00780
AT4357
Q06981
AT−6
− AUTOMATIC TRANSMISSIONSENSOR ROTOR (A340E)
1347 Author: Date:
1996 TOYOTA T100 (RM449U)
13. 5VZ−FE:
INSTALL SENSOR ROTOR
Install the lock ball and sensor rotor.
14. INSTALL SPEEDOMETER DRIVE GEAR AND BALL
(a) Install the speedometer drive gear and ball.
(b) Using a snap ring expander, install the snap ring.
15. INSTALL EXTENSION HOUSING AND GASKET
(a) Apply sealant or equivalent to the 6 bolts.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Install the extension housing with a new gasket to the
case.
(c) Install the 6 bolts.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
16. INSTALL REAR MOUNTING INSULATOR TO EXTEN-
SION HOUSING
Install the engine rear mounting insulator with the 4 bolts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Q06961
3RZ−FE
Z14780
5VZ−FE
− AUTOMATIC TRANSMISSIONSENSOR ROTOR (A340E)
AT−7
1348 Author: Date:
1996 TOYOTA T100 (RM449U)
17. 3RZ−FE:
INSTALL REAR MOUNTING BRACKET TO REAR SUP-
PORT MEMBER
Install the 7 bolts to the rear mounting bracket.
Torque:
Rear mounting side: 18 N·m (185 kgf·cm, 13 ft·lbf)
Frame side: 58 N·m (590 kgf·cm, 42 ft·lbf)
18. 5VZ−FE:
INSTALL REAR MOUNTING BRACKET TO REAR SUP-
PORT MEMBER
Install the 8 bolts from the rear mounting bracket.
Torque:
Rear mounting side: 18 N·m (185 kgf·cm, 13 ft·lbf)
Frame side: 58 N·m (590 kgf·cm, 42 ft·lbf)
19. INSTALL NO.2 VEHICLE SPEED SENSOR
(See page AT−10)
20. INSTALL SPEEDOMETER DRIVEN GEAR AND CON-
NECT SPEEDOMETER CABLE (See page AT−8)
21. INSTALL PROPELLER SHAFT (See page PR−9)

Downloaded from www.Manualslib.com manuals search engine Q04730
AT01W−02
Q06873
Z15613
A340E
SST
SST
A340F
Q07623
A340ESST
SST A340F
AT−8
− AUTOMATIC TRANSMISSIONSPEEDOMETER DRIVEN GEAR
1349 Author: Date:
1996 TOYOTA T100 (RM449U)
SPEEDOMETER DRIVEN GEAR
ON−VEHICLE REPAIR
1. DISCONNECT SPEEDOMETER CABLE AND RE-
MOVE SPEEDOMETER DRIVEN GEAR
(a) Loosen the serrated collar with pliers. Do not lose the felt
dust protector and washer.
(b) Disconnect the speedometer cable.
(c) Remove the bolt and locking plate. Pry out the speedom-
eter driven gear assembly.
(d) Remove the O−ring from the speedometer drive gear as-
sembly.
(e) Remove the clip and speedometer driven gear from the
speedometer driven gear sleeve.
2. REMOVE SPEEDOMETER DRIVEN GEAR OIL SEAL
Using SST, remove the oil seal.
SST 09921−00010
3. INSTALL SPEEDOMETER DRIVEN GEAR OIL SEAL
Using SST, install a new oil seal.
SST 09201−10000 (09201−01080)
Drive in depth: 20 mm (0.79 in.)
4. INSTALL SPEEDOMETER DRIVEN GEAR AND CON-
NECT SPEEDOMETER CABLE
(a) Install the clip and speedometer driven gear to the
speedometer driven gear sleeve.
(b) Install a new O−ring to the speedometer driven gear as-
sembly.
(c) Install the speedometer driven gear.
(d) Install the locking plate with the bolt.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(e) Connect the speedometer cable.