1996 TOYOTA T100 replace manual transmission

Downloaded from www.Manualslib.com manuals search engine MT053−01
Z03575
SST
RM0013
Socket Wrench
Z03576
MT−38
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE COUNTER GEAR FRONT
BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the bearing.
SST 09950−00020
(c) Replace the side race.
(d) Using a socket wrench and press, install a new bearing
and side race.
(e) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.00 − 2.05 (0.0787 − 0.0807)
B2.05 − 2.10 (0.0807 − 0.0827)
C2.10 − 2.15 (0.0827 − 0.0846)
D2.15 − 2.20 (0.0846 − 0.0866)
E2.20 − 2.25 (0.0866 − 0.0886)
F2.25 − 2.30 (0.0886 − 0.0906)
(f) Using a snap ring expander, install the snap ring.

Downloaded from www.Manualslib.com manuals search engine MT056−01
Z03583
Q07394
SST
− MANUAL TRANSMISSION (R150, R150F)FRONT BEARING RETAINER OIL SEAL
MT−41
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE FRONT BEARING RETAINER
OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00510), 09950−70010
(09951−07150)
Drive in depth:
11.7 ± 0.5 mm (0.461 ± 0.020 in.) from retainer end

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Q04410
Z03582
Q07365
SST
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
MT−43
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Remove the reverse restrict pin.
(1) Using a torx socket wrench (T40), remove the screw
plug.
(2) Using a pin punch and hammer, drive out the slotted
spring pin.
(3) Remove the reverse restrict pin.
(b) Inspect the reverse restrict pin.
Turn and push the reverse restrict pin by hand.
Check for smooth operation.
(c) Install the reverse restrict pin.
(1) Install the reverse restrict pin to the extension hous-
ing or transfer adaptor.
(2) Using a pin punch and hammer, drive in the slotted
spring pin, as shown.
(3) Apply sealant to the plug threads.
Sealant:
Part No. 08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(4) Using a torx socket wrench (T40), install and torque
the screw plug.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
2. 2WD:
IF NECESSARY, REPLACE EXTENSION HOUSING
OIL SEAL
(a) Remove the dust deflector.
(b) Using a screwdriver, pry out the oil seal.
(c) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00570), 09950−70010
(09951−07150)
Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(d) Install the deflector.

Downloaded from www.Manualslib.com manuals search engine Q07366
SST
MT−44
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
1996 TOYOTA T100 (RM449U)
3. 4WD:
IF NECESSARY, REPLACE TRANSFER ADAPTOR OIL
SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00570), 09950−70010
(09951−07150)
Drive in depth: 45.6 ± 0.5 mm (1.795 ± 0.020 in.)

Downloaded from www.Manualslib.com manuals search engine MT03I−01
MT−2
− MANUAL TRANSMISSION (W59)TROUBLESHOOTING
1301 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)
2. Oil (Wrong)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−4
MT−4
MT−6
MT−6
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MT−4
MT−6
MT−6
MT−6
Hard to shift or will not shift
1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)MT−18
MT−21
MT−30
MT−18
MT−21
MT−30
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−6
MT−6
MT−6
MT−6

Downloaded from www.Manualslib.com manuals search engine Q00855
Q07367
SST
WM0125
SST
Q07552
SSTSST
25mm MT−16
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
(b) Using a snap ring expander, remove the 2 snap rings.
HINT:
At the time of reassembly, please refer to the following item.
Make sure the snap ring is flush with the intermediate plate sur-
face.
22. REMOVE OUTPUT SHAFT AND COUNTER GEAR
FROM INTERMEDIATE PLATE
(a) Remove the output shaft, input shaft and counter gear as
a unit from the intermediate plate by pulling on the counter
gear and tapping on the intermediate plate with a plastic
hammer.
(b) Remove the input shaft from the output shaft.
HINT:
At the time of reassembly, please refer to the following items.
Before installing the output shaft, use SST to remove the
counter gear center bearing outer race.
SST 09950−60010 (09951−00510), 09950−70010
(09951−07150)
Install the outer race after installing the counter gear.
Install the output shaft into the intermediate plate by pull-
ing on the output shaft and tapping on the intermediate
plate.
HINT:
At the time of reassembly, please refer to the following items.
Apply gear oil to the needle roller bearing.
Install the needle roller bearing to the input shaft.
Install the input shaft and counter gear together.
Using SST and a hammer, install a new counter gear cen-
ter bearing outer race.
SST 09316−60011 (09316−00011)
Be careful not to damage the bearing rollers.
23. IF NECESSARY REPLACE SPEEDOMETER DRIVEN
GEAR OIL SEAL
(a) Using SST, remove the oil seal.
SST 09921−00010
(b) Coat the lip of oil seal with MP grease.
(c) Using SST, drive in a new oil seal.
SST 09201−10000 (09201−01080), 09950−70010
(09951−07150)
Drive in depth: 25 mm (0.98 in.)

Downloaded from www.Manualslib.com manuals search engine D00871
MT03Q−01
D00872
− MANUAL TRANSMISSION (W59)INPUT SHAFT
MT−19
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.5 mm (0.020 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.

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Q00857
Q00878
SST
Q00858
MT−20
− MANUAL TRANSMISSION (W59)INPUT SHAFT
1996 TOYOTA T100 (RM449U)
REPLACEMENT
IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the bearing.
(c) Using SST and a press, install a new bearing.
SST 09506−35010
(d) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
12.05 − 2.10 (0.0807 − 0.0827)
22.10 − 2.15 (0.0827 − 0.0846)
32.15 − 2.20 (0.0846 − 0.0866)
42.20 − 2.25 (0.0866 − 0.0886)
52.25 − 2.30 (0.0886 − 0.0906)
112.30 − 2.35 (0.0906 − 0.0925)
122.35 − 2.40 (0.0925 − 0.0945)
(e) Using a snap ring expander, install the snap ring.