1996 TOYOTA T100 transmission oil

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
EM−81
1996 TOYOTA T100 (RM449U)
16. w/ A/C:
INSTALL DRIVE BELT FOR A/C COMPRESSOR
17. INSTALL DRIVE BELT FOR PS PUMP
18. INSTALL RADIATOR ASSEMBLY
(See page CO−19)
19. FILL WITH ENGINE OIL
20. FILL WITH ENGINE COOLANT
21. INSTALL ENGINE UNDER COVER
22. INSTALL TRANSMISSION
(See page MT−4)
23. INSTALL HOOD
24. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
25. RECHECK ENGINE COOLANT AND ENGINE OIL
LEVELS

Downloaded from www.Manualslib.com manuals search engine SF0B5−02
P16016
P15974
− MFI (3RZ−FE)IDLE AIR CONTROL (IAC) VALVE
MF−31
983 Author: Date:
1996 TOYOTA T100 (RM449U)
IDLE AIR CONTROL (IAC) VALVE
ON−VEHICLE INSPECTION
1. INSPECT IAC VALVE OPERATION
(a) Initial conditions:
Engine at normal operating temperature
Idle speed set correctly
Transmission in neutral range
(b) Using SST, connect terminals TE1 and E1 of the
DLC1.
SST 09843−18020
(c) After engine rpm are kept at 1,000 − 1,500 rpm for 5 se-
conds, check that they return to idle speed.
If the rpm operation is not as specified, check the IAC valve, wir-
ing and ECU.
(d) Remove SST.
SST 09843−18020
2. INSPECT IAC VALVE RESISTANCE
NOTICE:
”Cold” and ”Hot” in the following sentences express the
temperature of the coils themselves. ”Cold” is from −10°C
(14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to
100°C (212°F).
(a) Disconnect the IAC valve connector.
(b) Using an ohmmeter, measure the resistance between ter-
minal +B and other terminals (RSC, RSO).
Resistance:
Cold: 21.5 − 28.5Ω
Hot: 17.0 − 24.5Ω
If resistance is not as specified, replace the IAC valve.
(c) Reconnect the IAC valve connector.

Downloaded from www.Manualslib.com manuals search engine SF0CI−03
P19970
SST
TE1 E1DLC1
DLC1
P21126
Ohmmeter RSC
+B
RSOIAC Valve
− SFI (5VZ−FE)IDLE AIR CONTROL (IAC) VALVE
SF−39
1045 Author: Date:
1996 TOYOTA T100 (RM449U)
IDLE AIR CONTROL (IAC) VALVE
ON−VEHICLE INSPECTION
1. INSPECT IAC VALVE OPERATION
(a) Initial conditions:
Engine at normal operating temperature
Idle speed check correctly
Transmission in neutral position
A/C switch OFF
(b) Using SST, connect terminals TE1 and E1 of the
DLC1.
SST 09843−18020
(c) After engine speed is kept at approx. 1,000 rpm for 5 se-
conds, check that it returns to idle speed.
If the engine speed operation is not as specified, check the IAC
valve, wiring and ECM.
(d) Remove the SST from the DLC1.
SST 09843−18020
2. INSPECT IAC VALVE RESISTANCE
NOTICE:
”Cold” and ”Hot” in the following sentences express the
temperature of the coils themselves. ”Cold” is from −10°C
(14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to
100°C (212°F).
(a) Disconnect the IAC valve connector.
(b) Using an ohmmeter, measure the resistance between ter-
minal +B and other terminals (RSC, RSO).
Resistance:
Cold: 17.0 − 24.5 Ω
Hot: 21.5 − 28.5 Ω
If resistance is not as specified, replace the IAC valve.
(c) Reconnect the IAC valve connector.
3. INSPECT AIR ASSIST SYSTEM
(a) Initial conditions:
Engine at normal operating temperature
Idle speed check correctly
Transmission in neutral position
A/C switch OFF

Downloaded from www.Manualslib.com manuals search engine MT – MANUAL TRANSMISSION (R150, R150F)

MANUAL TRANSMISSION SYSTEM MT-1
TROUBLESHOOTING MT-2
MANUAL TRANSMISSION UNIT (2WD) MT-3
MANUAL TRANSMISSION UNIT (4WD) MT-6
MANUAL TRANSMISSION ASSEMBLY MT-11
INPUT SHAFT MT-22
OUTPUT SHAFT MT-25
COUNTER GEAR AND REVERSE
IDLER GEAR MT-34
FRONT BEARING RETAINER OIL SEAL MT-40
EXTENSION HOUSING AND
TRANSFER ADAPTOR MT-42

Downloaded from www.Manualslib.com manuals search engine MT04J−01
MT−2
− MANUAL TRANSMISSION (R150, R150F)TROUBLESHOOTING
1257 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. Oil (Level low) 2WD
4WD
2. Oil (Wrong) 2WD
4WD
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−4
MT−7
MT−4
MT−7
MT−11
MT−11
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MT−4
MT−7
MT−11
MT−11
MT−11
Hard to shift or will not shift
1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)MT−22
MT−25
MT−34
MT−25
MT−34
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−11
MT−11
MT−11
MT−11

Downloaded from www.Manualslib.com manuals search engine MT0501
Down
ClothCounterclockwise
MT04O−02
Q06817
Installation
Front
Select Return Spring
Tip of Shift Lever
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
MT−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION SHIFT LEVER
(a) Remove the 4 screws and front console box.
(b) Remove the 4 screws and shift lever boot retainer.
(c) Cover the shift lever cap with a cloth.
(d) Then, pressing down on the shift lever cap, rotate it coun-
terclockwise to remove.
(e) Pull out the shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of the shift lever.
2. REMOVE TRANSFER SHIFT LEVER
Using snap ring pliers, remove the snap ring and pull out the
shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of shift lever.
3. RAISE VEHICLE AND DRAIN TRANSMISSION OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 2.2 liters (2.3 US qts, 1.9 Imp. qts)
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE FRONT AND REAR PROPELLER SHAFTS
(See page PR−10)
5. DISCONNECT SPEEDOMETER CABLE
6. DISCONNECT BACK−UP LIGHT SWITCH AND 4WD
INDICATOR SWITCH CONNECTORS
7. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
Remove the 4 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Q06907
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (4WD)
MT−9
1996 TOYOTA T100 (RM449U)
16. REMOVE TRANSFER FROM TRANSMISSION
(a) Remove the transfer adaptor rear mounting bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) 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.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the adaptor oil seal and shift the 2 shift fork
shafts to the high − 4 position.

Downloaded from www.Manualslib.com manuals search engine MT04R−01
Q06902
FIPG
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−13
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE BACK−UP LIGHT SWITCH
Torque: 44 N·m (450 kgf·cm, 32 ft·lbf)
2. 2WD:
REMOVE SPEEDOMETER DRIVEN GEAR
Remove the driven gear lock plate set bolt and driven gear.
Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
3. REMOVE CLUTCH HOUSING FROM TRANSMISSION
CASE
Remove the 9 bolts and clutch housing from the transmission
case.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
4. REMOVE CONTROL SHIFT LEVER RETAINER
(a) Remove the 6 (2WD) or 4 (4WD) bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the retainer and gasket (2WD) or oil deflector
(4WD).
5. REMOVE 2 RESTRICT PINS
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
6. 2WD:
REMOVE EXTENSION HOUSING
(a) Remove the shift lever housing set bolt.
Torque: 38 N·m (390 kgf·cm, 28 ft·lbf)
(b) Remove the 10 bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(c) Using a plastic hammer, tap the extension housing, re-
move the shift lever housing and shift and select lever.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or
equivalent