1996 TOYOTA T100 manual transmission

Downloaded from www.Manualslib.com manuals search engine Q04688
Z18883
BA
C
Q06800
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340F)
AT−35
1996 TOYOTA T100 (RM449U)
9. DISCONNECT SPEEDOMETER CABLE
(a) Loosen the serrated collar with pliers. Do not lose the felt
dust protector and washer.
(b) Disconnect the cable.
10. DISCONNECT NO.2 VEHICLE SPEED SENSOR CON-
NECTOR
11. DISCONNECT SOLENOID CONNECTOR
12. DISCONNECT TRANSFER NEUTRAL POSITION
SWITCH
13. DISCONNECT TRANSFER L4 POSITION SWITCH
14. DISCONNECT TRANSFER INDICATOR SWITCH
15. SEPARATE WIRE HARNESS FROM TRANSMISSION
AND TRANSFER
16. REMOVE CROSS SHAFT
(a) Remove the clip and disconnect the No.2 gear shifting
rod.
(b) Remove the nut, washer, 4 bolts and the cross shaft.
Torque:
A (Transmission side): 13 N·m (130 kgf·cm, 9 ft·lbf)
B (Frame side): 28 N·m (290 kgf·cm, 21 ft·lbf)
C (Nut): 13 N·m (130 kgf·cm, 9 ft·lbf)
17. DISCONNECT STARTER WIRE
(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the starter connector.
18. REMOVE OIL COOLER PIPE
(a) Remove the bolt and front side oil cooler pipe clamp.
(b) Remove the bolt and rear side oil cooler pipe clamp.
(c) Disconnect the 2 oil cooler pipes.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
19. DISCONNECT ATF TEMPERATURE SENSOR CON-
NECTOR
20. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR

Downloaded from www.Manualslib.com manuals search engine Q06801
Q06802
Q06881
Q02647
Q06804
AT−36
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340F)
1996 TOYOTA T100 (RM449U)
21. REMOVE STARTER
Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
22. REMOVE STIFFENER PLATE AND REAR END PLATE
Remove the 8 bolts, LH, RH stiffener plates and rear end plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
23. REMOVE FRONT STABILIZER BAR (See page
SA−127)
24. JACK UP TRANSMISSION
25. DISCONNECT REAR MOUNTING INSULATOR
(a) Remove the 2 bolts and dynamic damper.
Torque: 61 N·m (620 kgf·cm, 44 ft·lbf)
(b) Remove the 4 bolts and rear mounting bracket.
Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)
26. REMOVE REAR SUPPORT MEMBER
Remove the 8 bolts and support member.
Torque: 95 N·m (970 kgf·cm, 70 ft·lbf)
27. REMOVE TRANSMISSION
(a) Turn the crankshaft to gain access to each bolt, remove
the 6 bolts with holding the crankshaft pully bolt with a
wrench.
Torque: 41 N·m (420 kgf·cm, 30 ft·lbf)
(b) Disconnect the wire harness and connectors from the
transmission.
(c) Remove the 6 bolts and transmission.
Torque: 71 N·m (730 kgf·cm, 53 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine D00842
AT02F−01
− AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION UNIT (A340F)
AT−37
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. CHECK TORQUE CONVERTER CLUTCH INSTALLA-
TION
Using calipers and a straight edge, measure from the installed
surface of the transmission housing.
Correct distance: More than 17.95 mm (0.7067 in.)
2. INSTALL TRANSMISSION
Installation is in the reverse order of removal (See page
AT−34).
HINT:
After installation, adjust the shift lever position (See page
DI−265).
Fill ATF and check fluid level (See page DI−265).

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SST
AT02G−06
AT3306
Free Lock Hold
Turn
D00843
AT−38
− AUTOMATIC TRANSMISSIONTORQUE CONVERTER CLUTCH AND DRIVE PLATE
1379 Author: Date:
1996 TOYOTA T100 (RM449U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE−WAY CLUTCH
(a) Install SST in the inner race of one−way clutch.
SST 09350−30020 (09351−32010)
(b) Install SST so that it fits in the notch of the converter hub
and outer race of the one−way clutch.
SST 09350−30020 (09351−32020)
(c) With the torque converter clutch standing on its side,
check that the clutch locks when turned counterclock-
wise, and rotates freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch.
(d) Replace the converter if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If runout is not within the specification or if the ring gear is dam-
aged, replace the drive plate.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine AT4184
− AUTOMATIC TRANSMISSIONTORQUE CONVERTER CLUTCH AND DRIVE PLATE
AT−39
1380 Author: Date:
1996 TOYOTA T100 (RM449U)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate.
Set up a dial indicator, measure the torque corverter clutch
sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If runout is not within the specification, try to correct by reorient-
ing the installation of the converter clutch.
HINT:
Mark the position of the converter clutch to ensure the correct
installation.

Downloaded from www.Manualslib.com manuals search engine TR0CY−02
TF0626
Breather Hose
Transmission Side Transfer Side
TF0633
TF0655
TF0654
− TRANSFERTRANSFER UNIT
TR−3
1383 Author: Date:
1996 TOYOTA T100 (RM449U)
TRANSFER UNIT
REMOVAL
1. REMOVE TRANSFER WITH TRANSMISSION
M/T (See page MT−7)
A/T (See page AT−34)
HINT:
At the time of installation, shift the 2 shift fork shafts to the H4
position.
2. A/T:
REMOVE BREATHER HOSE
Disconnect the breather hose from transfer upper cover and
transmission control retainer.
Hose depth: 13 mm (0.51 in.) or more
3. REMOVE DYNAMIC DAMPER
Remove the 2 bolts and dynamic damper.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the trans-
mission.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
5. REMOVE PROPELLER SHAFT UPPER DUST COVER
AND TRANSFER FROM TRANSMISSION
(a) Remove the dust cover bolt from the bracket.
Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)
(b) Remove the transfer adapter rear mounting bolts.
(c) 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.

Downloaded from www.Manualslib.com manuals search engine PR01F−01
− PROPELLER SHAFTTROUBLESHOOTING
PR−1
1419 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. Center support bearing (Worn) 2WD
4WD
2. Sleeve yoke spline (Worn) 2WD
4WD
3. Spider bearing (Worn or stuck) 2WD
4WDPR−5
PR−13
PR−5
PR−13
PR−5
PR−13
Vibration
1. Transmission extension housing rear bushing (Runout)
2. Sleeve yoke spline (Stuck) 2WD
4WD
3. Propeller shaft (Runout) 2WD
4WD
4. Propeller shaft (Imbalance) 2WD
4WD−
PR−5
PR−13
PR−5
PR−13
PR−5
PR−13

Downloaded from www.Manualslib.com manuals search engine PR01H−01
R15507Matchmarks
R04164
SST
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY (2WD)
PR−3
1996 TOYOTA T100 (RM449U)
REMOVAL
REMOVE PROPELLER SHAFT
(a) Place matchmarks on the differential and propeller shaft
flanges.
(b) Remove the 4 bolts, washers and nuts.
(c) Remove the 2 mounting bolts and center support bearing
from the frame crossmember.
(d) Pull out the propeller shaft yoke from the transmission.
(e) Insert SST in the transmission to prevent oil leakage.
SST 09325−40010