1996 TOYOTA T100 manual transmission

Downloaded from www.Manualslib.com manuals search engine PP3LO−01
PP−86
− PREPARATIONPROPELLER SHAFT
135 Author: Date:
1996 TOYOTA T100 (RM449U)
PROPELLER SHAFT
SST (Special Service Tools)
09325−40010Transmission Oil PlugTransmission to prevent oil leakage
09330−00021Companion Flange Holding ToolCompanion flange holding
09332−25010Universal Joint Bearing Remover
& ReplacerSpider bearing removal and installa-
tion

Downloaded from www.Manualslib.com manuals search engine PP3K7−01
PP−88
− PREPARATIONSUSPENSION AND AXLE
137 Author: Date:
1996 TOYOTA T100 (RM449U)
SUSPENSION AND AXLE
SST (Special Service Tools)
09223−56010Crankshaft Rear Oil Seal
ReplacerRear axle
09226−10010Crankshaft Front & Rear Bearing
ReplacerFront differential
09308−00010Oil Seal PullerFront axle (4WD)
Front differential
Rear axle
Rear differential
09316−12010Transfer Bearing ReplacerRear differential
09316−20011Transfer Bearing ReplacerFront differential
09316−60011Transmission & Transfer Bearing
ReplacerFront deifferentian
Rear axle
(09316−00041)Replacer ”C”Front differential
(09316−00051)Replacer ”D”Rear axle
09330−00021Companion Flange Holding ToolFront differential
Rear differential
09350−20015TOYOTA Automatic Transmission
Tool SetFront differential
(09369−20040)Piston Spring Compressor Set
09308−10010Oil Seal PullerFront differential
Rear differential

Downloaded from www.Manualslib.com manuals search engine SS – SERVICE SPECIFICATIONS

STANDARD BOLT SS-1
MAINTENANCE SS-3
ENGINE MECHANICAL (3RZ-FE) SS-4
ENGINE MECHANICAL (5VZ-FE) SS-9
EMISSION CONTROL (3RZ-FE) SS-14
EMISSION CONTROL (5VZ-FE) SS-16
MFI (3RZ-FE) SS-17
SFI (5VZ-FE) SS-19
COOLING (3RZ-FE) SS-21
COOLING (5VZ-FE) SS-23
LUBRICATION (3RZ-FE) SS-25
LUBRICATION (5VZ-FE) SS-27
IGNITION (3RZ-FE) SS-29
IGNITION (5VZ-FE) SS-31
STARTING (3RZ-FE) SS-33
STARTING (5VZ-FE) SS-35
CHARGING (3RZ-FE) SS-37
CHARGING (5VZ-FE) SS-39
CLUTCH SS-41
MANUAL TRANSMISSION (R150,
R150F) SS-43
MANUAL TRANSMISSION (W59) SS-46
AUTOMATIC TRANSMISSION SS-49
TRANSFER SS-53
PROPELLER SHAFT SS-56
SUSPENSION AND AXLE SS-58
BRAKE SS-69
STEERING SS-71
SUPPLEMENTAL RESTRAINT SYSTEM SS-75
BODY ELECTRICAL SS-77
BODY SS-80
AIR CONDITIONING SS-82

Downloaded from www.Manualslib.com manuals search engine SS093−02
− SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
SS−7
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Throttle body x Air intake chamber2020014
Spark plug x Cylinder head1920014
Cylinder head x Cylinder block 1st
2nd
3rd39
Turn 90°
Turn 90°
40029
Cylinder head x Timing chain cover2121015
Camshaft bearing cap x Cylinder head15.516012
Camshaft timing gear x Camshaft73.575054
Distributor gear x Camshaft4646534
Chain tensioner x Cylinder head2121015
Engine hanger x Cylinder head4242030
Exhaust manifold x Cylinder head4950036
Heat insulator x Exhaust manifold5.55548 in.·lbf
Front exhaust pipe x Exhaust manifold6263046
No.1 support bracket x Transmission3940029
No.1 support bracket clamp bolt1919514
Front exhaust pipe x TWC3940029
Intake manifold x Cylinder head2930022
Delivery pipe x Intake manifold2121015
Fuel inlet tube x Fuel filter2930022
Fuel inlet tube x Delivery pipe2930022
EGR valve x Air intake chamber, EGR pipe1919514
EGR vacuum modulator x Air intake chamber8.58574 in.·lbf
EGR pipe x Exhaust manifold2020015
EGR pipe x Cylinder head1818514
Cylinder head rear cover x Cylinder head13.513510
Water outlet x Cylinder head2020014
PS pump bracket x Cylinder head2020014
PS pump bracket x PS pump5859043
PS pump x PS pump pulley4344032
PS pump idler pulley x Cylinder head2020014
Balance shaft drive gear x Balance shaft2525018
No.2 chain tensioner, No.3 vibration damper x Cylinder block1818513
No.2 vibration damper x Cylinder block2727020
No.1 vibration damper x Cylinder block1818513
No.1 timing chain tensioner slipper x Cylinder block2727020
Timing chain cover x Cylinder block Bolt A
Bolt B
Bolt C
Nut D20
24.5
44
20200
250
440
20014
18
32
14
Timing chain cover mounting bolt1818513
No.1 water bypass pipe mounting nut2020014
Crankshaft pulley x Crankshaft2602,650193
No.2 and No.3 crankshaft pulley x Crankshaft pulley2525018

Downloaded from www.Manualslib.com manuals search engine SS−8
− SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
1996 TOYOTA T100 (RM449U) Oil strainer x Cylinder block
1818513
Oil pan x Cylinder block12.51309
Crankshaft position sensor x Timing chain cover8.58574 in.·lbf
Generator bracket x Cylinder block74.576055
Generator bracket x Timing chain cover1818513
Generator adjusting bar x Timing chain cover63.565047
A/C compressor bracket x Cylinder block4444032
A/C compressor x A/C compressor bracket2525018
Water pump pulley x Water pump2121016
Connecting rod cap x Connecting rod 1st
2nd45
Turn 90°46033
Main bearing cap x Cylinder block 1st
2nd39
Turn 90°40029
No.1 balance shaft x Timing gear3636526
No.2 balance shaft x Timing sprocket3636526
Balance shaft x Cylinder block1818513.4
Rear oil seal retainer x Cylinder block13.51359.7
RH, LH engine mounting bracket x Cylinder block4545034
Oil dipstick guide x LH engine mounting bracket2020014
Oil filter bracket union, Engine coolant drain plug x Cylinder block2525018
Oil filter bracket x Cylinder block2829021
Water bypass pipe x Cylinder block2020014
Knock sensor x Cylinder block3738027
Fuel filter x Cylinder block2020014
Rear end plate x Cylinder block1818513
Rear end plate x Water bypass pipe2020014
Flywheel x Crankshaft 1st
2nd26.5
Turn 90°27019
Front crossmember x Engine rear mounting bracket2526019
Front exhaust pipe clamp x Exhaust manifold6263046
Exhaust support bracket x Transmission3940029
Front exhaust pipe clamp1919514
Front exhaust pipe x TWC3940029
Engine rear mounting bracket x Engine rear mounting insulator1818313
Engine front mounting insulator x Frame3838728
Clutch release cylinder bracket x Transmission3940029
Clutch release cylinder x Transmission131309
Stabilizer bar bracket mounting bolt3030622
Stabilizer bar x Lower suspension arm131309
Intake air connector x Cylinder head1818513
Radiator x Body1818513

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSENGINE MECHANICAL (5VZ−FE)
SS−13
1996 TOYOTA T100 (RM449U) Engine mounting bracket x Cylinder block
4444032
Oil filter union x Cylinder block2525018
Oil pressure switch x Cylinder block1515011
Generator adjusting bar x Cylinder block4242031
Knock sensor x Cylinder block3940029
No.2 idler pulley bracket x Cylinder block3838028
Water bypass pipe x Cylinder block8.58575 in.·lbf
Rear end plate x Cylinder block7.57566 in.·lbf
Drive plate x Crankshaft8385063
Flywheel x Crankshaft8585063
Clutch release cylinder x Transmission121209
Stabilizer bar bracket mounting bolt3030622
Stabilizer bar x Lower suspension arm131309
Front exhaust pipe x Exhaust crossover pipe6263046
Front exhaust pipe x Center exhaust pipe4849035
Front exhaust pipe support bracket x Front exhaust pipe4445033
Front exhaust pipe support bracket x Transmission4445033
Center exhaust pipe x Tailpipe4849035
Center exhaust pipe support bracket x Body2930021

Downloaded from www.Manualslib.com manuals search engine SS07V−01
− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (R150, R150F)
SS−43
217 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION(R150, R150F)
SERVICE DATA
Output shaft 1st gear journal diameterMin.38.860 mm (1.5299 in.)
Output shaft 2nd gear journal diameterMin.46.860 mm (1.8449 in.)
Output shaft 3rd gear journal diameterMin.37.860 mm (1.4905 in.)
Output shaft flange thicknessMin.4.70 mm (0.1850 in.)
Output shaft runoutMax.0.06 mm (0.0024 in.)
Gear thrust clearance 1st STD
Max.0.15−0.45 mm (0.0059−0.0177 in.)
0.50 mm (0.0197 in.)
Gear thrust clearance 2nd STD
Max.0.10−0.25 mm (0.0039−0.0098 in.)
0.30 mm (0.0118 in.)
Gear thrust clearance 3rd STD
Max.0.10−0.25 mm (0.0039−0.0098 in.)
0.30 mm (0.0118 in.)
Gear radial clearance 1st STD
Max.0.020−0.073 mm (0.0008−0.0029 in.)
0.160 mm (0.0063 in.)
Gear radial clearance 2nd STD
Max.0.015−0.068 mm (0.0006−0.0027 in.)
0.160 mm (0.0063 in.)
Gear radial clearance 3rd STD
Max.0.015−0.068 mm (0.0006−0.0027 in.)
0.160 mm (0.0063 in.)
Shift fork to hub sleeve clearanceMax.1.0 mm (0.039 in.)
Synchronizer ring to gear clearanceMin.0.8 mm (0.031 in.)
Input shaft snap ring thickness
Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.10−2.15 mm (0.0827−0.0846 in.)
2.15−2.20 mm (0.0846−0.0866 in.)
2.20−2.25 mm (0.0866−0.0886 in.)
2.25−2.30 mm (0.0886−0.0906 in.)
2.30−2.35 mm (0.0906−0.0925 in.)
2.35−2.40 mm (0.0925−0.0945 in.)
2.40−2.45 mm (0.0945−0.0965 in.)
Output shaft snap ring thickness
Clutch hub No.1 Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.30−2.35 mm (0.0906−0.0925 in.)
2.35−2.40 mm (0.0925−0.0945 in.)
2.40−2.45 mm (0.0945−0.0965 in.)
2.45−2.50 mm (0.0965−0.0984 in.)
2.50−2.55 mm (0.0984−0.1004 in.)
2.55−2.60 mm (0.1004−0.1024 in.)
2.60−2.65 mm (0.1024−0.1043 in.)
Output shaft snap ring thickness
Clutch hub No.2 Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
1.80−1.85 mm (0.0709−0.0728 in.)
1.85−1.90 mm (0.0728−0.0748 in.)
1.90−1.95 mm (0.0748−0.0768 in.)
1.95−2.00 mm (0.0768−0.0787 in.)
2.00−2.05 mm (0.0787−0.0807 in.)
2.05−2.10 mm (0.0807−0.0827 in.)
2.10−2.15 mm (0.0827−0.0846 in.)

Downloaded from www.Manualslib.com manuals search engine SS−44
− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (R150, R150F)
218 Author: Date:
1996 TOYOTA T100 (RM449U) Output shaft snap ring thickness
Rear Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
Mark H
Mark J
Mark K
Mark L
Mark M
Mark N
Mark P
Mark Q
Mark R
Mark S
2.65−2.70 mm (0.1043−0.1063 in.)
2.70−2.75 mm (0.1063−0.1083 in.)
2.75−2.80 mm (0.1083−0.1102 in.)
2.80−2.85 mm (0.1102−0.1122 in.)
2.85−2.90 mm (0.1122−0.1142 in.)
2.90−2.95 mm (0.1142−0.1161 in.)
2.95−3.00 mm (0.1161−0.1181 in.)
3.00−3.05 mm (0.1181−0.1201 in.)
3.05−3.10 mm (0.1201−0.1220 in.)
3.10−3.15 mm (0.1220−0.1240 in.)
3.15−3.20 mm (0.1240−0.1260 in.)
3.20−3.25 mm (0.1260−0.1280 in.)
3.25−3.30 mm (0.1280−0.1299 in.)
3.30−3.35 mm (0.1299−0.1319 in.)
3.35−3.40 mm (0.1319−0.1339 in.)
3.40−3.45 mm (0.1339−0.1358 in.)
3.45−3.50 mm (0.1358−0.1378 in.)
Counter gear roller bearing journal diameterMin.27.860 mm (1.0968 in.)
Counter 5th gear thrust clearance STD
Max.0.10−0.35 mm (0.0039−0.0138 in.)
0.40 mm (0.0157 in.)
Counter 5th radial clearance STD
Max.0.015−0.068 mm (0.0006−0.0027 in.)
0.160 mm (0.0063 in.)
Reverse idler gear radial clearance STD
Max.0.040−0.082 mm (0.0016−0.0032 in.)
0.130 mm (0.0051 in.)
Reverse idler gear to shift arm clearance STD
Max.0.05−0.35 mm (0.0020−0.0138 in.)
0.50 mm (0.0197 in.)
Counter gear snap ring thickness
Front Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
2.00−2.05 mm (0.0787−0.0807 in.)
2.05−2.10 mm (0.0807−0.0827 in.)
2.10−2.15 mm (0.0827−0.0846 in.)
2.15−2.20 mm (0.0846−0.0866 in.)
2.20−2.25 mm (0.0866−0.0886 in.)
2.25−2.30 mm (0.0886−0.0906 in.)
Counter gear snap ring thickness
Rear Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.80−2.85 mm (0.1102−0.1122 in.)
2.85−2.90 mm (0.1122−0.1142 in.)
2.90−2.95 mm (0.1142−0.1161 in.)
2.95−3.00 mm (0.1161−0.1181 in.)
3.00−3.05 mm (0.1181−0.1201 in.)
3.05−3.10 mm (0.1201−0.1220 in.)
3.10−3.15 mm (0.1220−0.1240 in.)
Oil seal drive in depth
Speedometer driven gear
Front bearing retainer (from retainer end)
Extension housing
Transfer adaptor
25 mm (0.98 in.)
11.7 ± 0.5 mm (0.461 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
45.6 ± 0.5 mm (1.795 ± 0.020 in.)