1996 TOYOTA T100 torque

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 TR0CZ−01
TF0629
TF0447
Q09400
FIPG
− TRANSFERTRANSFER ASSEMBLY
TR−7
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE SPEEDOMETER DRIVEN GEAR
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
2. REMOVE TRANSFER INDICATOR SWITCH
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
3. A/T:
REMOVE TRANSFER L4 AND NEUTRAL POSITION
SWITCH
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
HINT:
At the time of installation, check the following items.
Check to see that the input shaft and output shafts rotate
smoothly.
Check to see that shifting can be made smoothly to all
position.
4. A/T:
REMOVE SHIFT GEAR HEAD NO.1 AND NO.2
(a) Using a pin punch and hammer, drive out the 2 slotted
spring pins.
(b) Remove the 2 shift gear heads.
5. REMOVE FRONT RETAINER
(a) Remove the 7 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the bolts.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a plastic hammer, tap the front retainer and remove
it.
HINT:
At the time of installation, please refer to the following items.
Remove any FIPG material and be careful not to drop oil
on the contacting surfaces of the front retainer.
Apply FIPG to the front retainer, as shown.
FIPG:
Part No.08826−00090, THREE BOND 1281,
LOCTITE 242 or equivalent

Downloaded from www.Manualslib.com manuals search engine TF0448
TF0614
TF0451
SST
Q06503
SST TR−8
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
6. M/T:
REMOVE CONTROL RETAINER
(a) Remove the 4 bolts, control retainer and gasket.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
HINT:
At the time of installation, install a new gasket.
(b) Remove the select return spring from the retainer.
7. A/T:
REMOVE UPPER COVER AND OIL DEFLECTOR
Remove the 4 bolts, upper cover, 2 gaskets and oil deflector.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
HINT:
At the time of installation, install a new gasket.
8. REMOVE FRONT COMPANION FLANGE
(a) Using a chisel and hammer, loosen the staked part of the
nut.
HINT:
At the time of installation, stake a new lock nut.
(b) Using SST to hold the flange, remove the companion
flange lock nut.
SST 09330−00021
Torque: 118 N·m (1,200 kgf·cm, 87 ft·lbf)
(c) Using SST, remove the companion flange.
SST 09950−40010
9. REMOVE REAR COMPANION FLANGE
Remove the rear companion flange in the same way as the front
companion flange.
HINT:
At the time of installation, please refer to the following items.
Front companion flange bolts are silver.
Rear companion flange bolts are black.

Downloaded from www.Manualslib.com manuals search engine TF0453
F02979
FIPG
TF0454
TF0455
Z14087
FIPG
− TRANSFERTRANSFER ASSEMBLY
TR−9
1996 TOYOTA T100 (RM449U)
10. REMOVE EXTENSION HOUSING
(a) Remove the 5 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the bolts.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a plastic hammer, tap the extension housing and
remove it.
HINT:
At the time of installation, please refer to the following items.
Remove any FIPG material and be careful not to drop oil
on the contacting surfaces of the extension housing.
Apply FIPG to the extension housing, as shown.
FIPG:
Part No.08826−00090,
THREE BOND 1281 or equivalent
11. REMOVE SPEEDOMETER DRIVE GEAR
(a) Remove the speedometer drive gear.
HINT:
At the time of installation, please refer to the following item.
Make sure to install the speedometer drive gear in the correct
direction.
(b) Using a magnetic finger, remove the ball from the rear out-
put shaft.
12. SEPARATE FRONT CASE AND REAR CASE
(a) Remove the 12 bolts.
Torque: 28 N·m (285 kgf·cm, 20 ft·lbf)
(b) Using a plastic hammer, tap the rear case and separate
the front case and rear case.
HINT:
At the time of installation, please refer to the following items.
Shift the high and low clutch sleeve to low side (rear side)
and assemble the front case and rear case.
Remove any FIPG material and be careful not to drop oil
on the contacting surfaces of the rear case.
Apply FIPG to the rear case, as shown.
FIPG:
Part No.08826−00090,
THREE BOND 1281 or equivalent

Downloaded from www.Manualslib.com manuals search engine TF0457
TF0458
TF0459
TF0619F03415
M/T:
A/T: TR−10
− TRANSFERTRANSFER ASSEMBLY
1996 TOYOTA T100 (RM449U)
13. REMOVE STRAIGHT SCREW PLUGS, SPRINGS AND
LOCKING BALLS
(a) Using a hexagon wrench, remove the 2 straight screw
plugs.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the plugs.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a magnetic finger, remove the spring and ball from
the both holes.
14. REMOVE FRONT DRIVE FORK SHAFT, FORK,
SPRING AND STOPPER
(a) Using a pin punch and hammer, drive out the 2 slotted
spring pins.
HINT:
When the pin is removed from the front drive fork shaft, the shaft
will spring loose if the pin punch is removed, so keep the pin
punch inserted in the shaft hole.

Downloaded from www.Manualslib.com manuals search engine Q10176
TF0467
TF0468
TF0470
TF0471
− TRANSFERTRANSFER ASSEMBLY
TR−13
1996 TOYOTA T100 (RM449U)
17. M/T:
REMOVE SYNCHRONIZER RING FROM INPUT
SHAFT
HINT:
At the time of installation, please refer to the following items.
Apply gear oil to the synchronizer ring.
Align the synchronizer ring slots with the shifting keys,
and install it on the high and low clutch hub.
18. REMOVE SEPARATOR WITH OIL STRAINER
(a) Remove the 3 bolts and the separator with the oil strainer.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the O−ring from the oil strainer pipe.
HINT:
At the time of installation, please refer to the following item.
Coat a new O−ring with gear oil and install it to the oil strainer
pipe.
19. REMOVE OIL PUMP BODY ASSEMBLY
Remove the 3 bolts and the oil pump body assembly.
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
20. REMOVE OIL PUMP DRIVE GEAR
21. REMOVE PLANETARY GEAR ASSEMBLY WITH
INPUT SHAFT
(a) Using a snap ring expander, remove the snap ring.
(b) Pull out the planetary gear assembly with the input shaft.
HINT:
At the time of installation, please refer to the following item.
If necessary, heat the front case to about 70°C (158°F).

Downloaded from www.Manualslib.com manuals search engine TF0477
TF0478
TF0479
TF0507
− TRANSFERTRANSFER ASSEMBLY
TR−15
1996 TOYOTA T100 (RM449U)
(b) Remove the input gear stopper, thrust bearing, race and
the 2 pins.
HINT:
At the time of installation, apply gear oil to the thrust bearing and
race.
25. REMOVE INPUT SHAFT, THRUST BEARING AND
RACE
26. REMOVE PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring.
HINT:
At the time of installation, please refer to the following item.
Be sure the end gap of the snap ring is not aligned with the up-
per side of the case.
(b) Remove the plug, spring and pin.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the plug.
Sealant:
Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Remove the planetary ring gear.
HINT:
At the time of installation, make sure to install the ring gear in
the correct direction.

Downloaded from www.Manualslib.com manuals search engine TR0D0−01
TF0547
TF0485
TR−18
− TRANSFEROIL PUMP BODY
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. CHECK OIL PUMP OPERATION
Install the oil pump drive gear to the drive rotor and check that
the drive rotor turns smoothly.
2. REMOVE STRAIGHT SCREW PLUG, SPRING, BALL
AND SEAT
(a) Using a hexagon wrench, remove the straight screw plug.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, apply liquid sealer to the plug.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Using a magnetic finger remove the spring and ball.
(c) Using SST, pull out the seat.
SST 09921−00010
(d) Remove the O−ring from the seat.
HINT:
At the time of reassembly, please refer to the following items.
Install a new O−ing to the seat.
When installing the seat, push the seat until it touches the
bottom of the hole in the body.
3. REMOVE OIL PUMP PLATE
(a) Using a torx socket wrench (T30), unscrew the 3 torx
screws.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
(b) Remove the oil pump plate.
4. REMOVE DRIVE ROTOR AND DRIVEN ROTOR
HINT:
At the time of reassembly, apply gear oil to the both rotors.