1996 TOYOTA T100 key

Downloaded from www.Manualslib.com manuals search engine TR021−02
Z19022
A/T:
M/T:High and Low Clutch Sleeve
High and Low Clutch Hub
 Key Retainer High and Low Clutch Hub
High and Low Hub Sleeve
Snap RingShifting Key Spring Snap Ring
Ball
Bearing
Spacer Rear Output Shaft
Shifting Key Spring
Front Drive Clutch Sleeve
Drive SprocketNeedle Roller Bearing
Shifting Key
Synchronizer Ring
 Non−reusable partShifting Key
− TRANSFERREAR OUTPUT SHAFT
TR−23
1403 Author: Date:
1996 TOYOTA T100 (RM449U)
REAR OUTPUT SHAFT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine TR0D3−01
TF0516
TF0517
TF0549
TF0518
SST
TF0620
TR−24
− TRANSFERREAR OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust clear-
ance.
Standard clearance:
0.10 − 0.25 mm (0.0039 − 0.0098 in.)
Maximum clearance: 0.25 mm (0.0098 in.)
If the clearance exceeds the maximum, replace the drive
sprocket.
2. M/T:
REMOVE HIGH AND LOW HUB SLEEVE
ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the hub sleeve and 3 shifting keys.
(c) Using a press, remove the clutch hub, 2 key springs and
key retainer.
3. A/T:
REMOVE HIGH AND LOW HUB SLEEVE
ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the hub sleeve.
(c) Using a press, remove the clutch hub.
4. REMOVE REAR BEARING, SPACER AND DRIVE
SPROCKET WITH FRONT DRIVE CLUTCH SLEEVE
ASSEMBLY
(a) Using SST and a press, remove the bearing.
SST 09950−00020
(b) Remove these parts:
Spacer and ball
Drive sprocket with front drive hub and hub sleeve
Needle roller bearing
Synchronizer ring

Downloaded from www.Manualslib.com manuals search engine TF0531
− TRANSFERREAR OUTPUT SHAFT
TR−25
1996 TOYOTA T100 (RM449U)
5. REMOVE 3 SHIFTING KEYS AND 2 KEY SPRINGS
FROM FRONT DRIVE HUB ASSEMBLY
Using a screwdriver, remove the 2 shifting key springs and 3
shifting keys.

Downloaded from www.Manualslib.com manuals search engine TR024−02
TF0621
TF0624
Shifting
Key
Q02329
Slots
TF0532
SST
TF0516
− TRANSFERREAR OUTPUT SHAFT
TR−27
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. INSTALL FRONT DRIVE CLUTCH HUB AND HUB
SLEEVE
(a) Install the front drive hub sleeve onto the clutch hub.
HINT:
Make sure to install the hub sleeve in the correct direction.
(b) Install the 3 shifting keys and 2 springs.
NOTICE:
Install the key springs positioned so that their end gaps are
not in line.
2. INSTALL DRIVE SPROCKET WITH FRONT DRIVE
HUB SLEEVE ASSEMBLY, SPACER AND REAR
BEARING
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Install the synchronizer ring.
(c) Install the needle roller bearing in the drive sprocket.
(d) Install the drive sprocket with the front drive hub sleeve.
(e) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(f) Install the spacer to align it with the ball.
(g) Using SST and a press, install the rear bearing with the
outer race snap ring groove toward the rear.
SST 09316−60011 (09316−00011, 09316−00071)
3. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust clear-
ance.
Standard clearance:
0.10 − 0.25 mm (0.0039 − 0.0098 in.)

Downloaded from www.Manualslib.com manuals search engine TF0528
Shifting
Key
Shifting
Key SpringFront M/T:
TF0690
Front A/T:
TF0553
SST
TF0550
TF0550
TR−28
− TRANSFERREAR OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
4. M/T:
INSERT HIGH AND LOW CLUTCH HUB INTO HUB
SLEEVE
(a) Install the clutch hub and 3 shifting keys to the hub sleeve.
(b) Install the 2 shifting key springs under the 3 shifting keys.
NOTICE:
Install the key springs positioned so that their end gaps are
not in line.
5. A/T:
INSERT HIGH AND LOW CLUTCH HUB INTO HUB
SLEEVE
Install the clutch hub to the hub sleeve.
6. M/T:
INSTALL HIGH AND LOW HUB SLEEVE ASSEMBLY
(a) Using SST and a hammer, drive in a new key retainer.
SST 09316−60011 (09316−00011)
NOTICE:
Be careful not to deform or damage the key retainer.
(b) Using a press, install the high and low hub sleeve assem-
bly.
7. A/T:
INSTALL HIGH AND LOW HUB SLEEVE ASSEMBLY
Using a press, install the high and low hub sleeve assembly.

Downloaded from www.Manualslib.com manuals search engine Z18646
A/T:Key Cylinder
Key Unlock
Warning Switch
Ignition Switch
Column Upper
BracketKey Cylinder
Column Upper Bracket
Column Tube
Key Unlock
Warning Switch
Ignition Switch
 Bushing
Column Upper Clamp
 Tapered−Head Bolt
 Snap Ring
Main Shaft Assembly
Non−reusable part
Molybdenum disulfide lithium base grease 
35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
SR−12
− STEERINGNON−TILT STEERING COLUMN
1686 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine R04668
SR079−01
R04670
R11778
R01835
− STEERINGNON−TILT STEERING COLUMN
SR−17
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT COLUMN UPPER BRACKET
Check that the steering lock mechanism operates properly.
2. IF NECESSARY, REPLACE KEY CYLINDER
(a) Place the ignition key at the ACC position.
(b) Push down the stop pin with a thin rod, and pull out the
key cylinder.
(c) Install a new key cylinder.
HINT:
Make sure the ignition key is at the ACC position.
3. INSPECT IGNITION SWITCH AND KEY UNLOCK
WARNING SWITCH (See page BE−12)
4. IF NECESSARY, REPLACE IGNITION SWITCH AND
KEY UNLOCK WARNING SWITCH
(a) Remove the 3 screws.
(b) Install a new switches with the 3 screws.
5. INSPECT BEARING
Check the bearing rotation condition and check for abnormal
noise.
If the bearing is worn or damaged, replace the column tube/col-
umn upper tube.
6. IF NECESSARY, REPLACE BUSHING
(a) TILT STEERING COLUMN:
Remove the snap ring from the column lower tube.
(b) Using a screwdriver, remove the bushing from the column
tube/column lower tube.
NOTICE:
Be careful not to damage the column tube.
(c) Coat the inside of new bushing with molybdenum disul-
fide lithium base grease.

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Tilt Pawl Stopper
Tilt Lever
Tilt Lever Lock Shaft
Tension Spring
Compression Spring
Bearing Thrust Collar
 BearingWasher
Tilt Pawl
Column Upper Tube
 Snap Ring
Tum Signal Bracket
Tilt Lever
Assembly
Tilt Sub Lever
Tilt Pawl Stopper
Main Shaft Assembly
Stopper
Collar
A/T:
Key Cylinder
Key Unlock
Warning
Switch
Tilt Lever Ratainer
Column Upper
Bracket Ignition
Switch
 E−ringBolt Tilt No.2
Bushing Tension Spring
Key Unlock Warning Switch
Ignition Switch
Column Upper
Bracket
Column LowerTilt Lever
Ratainer
 E−ring
Tension
Speing
Tilt No.2 Bolt Tube
 Bushing
Sliding York Sub−Assembly
Non−reusable part
Molybdenum disulfide lithium base grease Snap Ring
 tapered−Head Bolt
Column Upper Clamp Key Cylinder
Tilt Pawl
35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
7.8 (80, 69 in.·lbf)
5.9 (60, 52 in.·lbf)
7.8 (80, 69 in.·lbf)
15 (150, 11)
2.0 (20, 17 in.·lbf)
− STEERINGTILT STEERING COLUMN
SR−25
1699 Author: Date:
1996 TOYOTA T100 (RM449U)