1996 TOYOTA T100 transmission oil

Downloaded from www.Manualslib.com manuals search engine Z03540
RM0010
Q07393
SST
Q07552
SST
SST
25 mm MT−20
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
30. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft toward the rear.
HINT:
At the time of the reassembly, please refer to the following item.
Align the reverse shift arm to the reverse idler gear shaft.
31. REMOVE OUTPUT SHAFT CENTER BEARING SNAP
RING
Using a snap ring expander, remove the snap ring.
32. REMOVE OUTPUT SHAFT AND COUNTER GEAR
FROM INTERMEDIATE PLATE
(a) Remove the output shaft, counter gear and input shaft 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 with the needle roller bearing from
the output shaft.
33. REMOVE COUNTER REAR BEARING FROM INTER-
MEDIATE PLATE
Using SST and a hammer, remove the counter rear bearing.
SST 09950−60010 (09951−00620), 09950−70010
(09951−07150)
34. 2WD:
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 MT04S−05
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−21
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MT−13).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

Downloaded from www.Manualslib.com manuals search engine MT04Z−01
Q06699
Front
Q00888
Q06700
Front
Z03558
MT−30
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL CLUTCH HUB NO.2 INTO HUB SLEEVE NO.2
(a) Install the clutch hub No.2 and shifting keys to the hub
sleeve No.2.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not
aligned.
2. INSTALL CLUTCH HUB NO.1 INTO REVERSE GEAR
(a) Install the 3 shifting key springs to the clutch hub No.1.
(b) While pushing the shifting key spring with a screwdriver,
install the 3 shifting keys.
(c) While pushing the 3 shifting keys, install the clutch hub
No.1 to the reverse gear, as shown.
3. INSTALL 3RD GEAR AND HUB SLEEVE NO.2 ON
OUTPUT SHAFT
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Install the needle roller bearing in the 3rd gear.

Downloaded from www.Manualslib.com manuals search engine GM0060
WM0116
RM0023
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−31
1996 TOYOTA T100 (RM449U)
(d) Using a press, install the 3rd gear and hub sleeve No.2.
4. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A1.80 − 1.85 (0.0709 − 0.0728)
B1.85 − 1.90 (0.0728 − 0.0748)
C1.90 − 1.95 (0.0748 − 0.0768)
D1.95 − 2.00 (0.0768 − 0.0787)
E2.00 − 2.05 (0.0787 − 0.0807)
F2.05 − 2.10 (0.0807 − 0.0827)
G2.10 − 2.15 (0.0827 − 0.0846)
(b) Using a snap ring expander, install the snap ring.
5. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MT−26)
6. INSTALL 2ND GEAR AND REVERSE GEAR
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Align the projection of the synchronizer inner ring with the
slots of the clutch hub No.1.
(d) Install the needle roller bearing in the 2nd gear.
(e) Using a press, install the 2nd gear assembly and reverse
gear assembly.

Downloaded from www.Manualslib.com manuals search engine Z03560
Z03563
Z03564
Z03565
2WD: 4WD:
SST
SST MT−32
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
7. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.30 − 2.35 (0.0906 − 0.0925)
B2.35 − 2.40 (0.0925 − 0.0945)
C2.40 − 2.45 (0.0945 − 0.0965)
D2.45 − 2.50 (0.0965 − 0.0984)
E2.50 − 2.55 (0.0984 − 0.1004)
F2.55 − 2.60 (0.1004 − 0.1024)
G2.60 − 2.65 (0.1024 − 0.1043)
(b) Using a screwdriver and hammer, install the snap ring.
8. INSTALL SPACER AND 1ST GEAR ASSEMBLY
(a) Install the spacer on the output shaft.
(b) Apply gear oil to the needle roller bearing.
(c) Assemble the 1st gear, synchronizer ring and needle roll-
er bearing.
(d) Install the assembly on the output shaft with the synchro-
nizer ring slots aligned with the shifting keys.
9. INSTALL STRAIGHT PIN AND 1ST GEAR THRUST
WASHER
Install the 1st gear thrust washer onto the output shaft with the
straight pin aligned with the 1st gear thrust washer.
10. INSTALL OUTPUT SHAFT CENTER BEARING
(a) 2WD:
Using SST and a hammer, drive in the bearing with the
outer race snap ring groove toward the rear.
SST 09309−35010
(b) 4WD:
Using SST and a hammer, drive in the bearing with the
outer race snap ring groove toward the rear.
SST 09316−60011 (09316−00011, 09316−00071)

Downloaded from www.Manualslib.com manuals search engine MT055−01
RM0322 Non−reusable partFront Bearing Retainer Oil Seal MT−40
− MANUAL TRANSMISSION (R150, R150F)FRONT BEARING RETAINER OIL SEAL
1295 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BEARING RETAINER OIL SEAL
COMPONENTS

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

Downloaded from www.Manualslib.com manuals search engine MT058−04
Z16044
4WD:
Slotted Spring PinTransfer Adaptor
 Oil Seal
 O−Ring
Dust Deflector
 Oil Seal 2WD: Oil Receiver Reverse Restrict Pin
Oil Receiver PipeOil Receiver Reverse Restrict Pin
Extension Housing
 Non−reusable part
 Precoated partSlotted Spring PinSpeedometer Driven Gear
Plug

Plug

Plug MT−42
− MANUAL TRANSMISSION (R150, R150F)EXTENSION HOUSING AND TRANSFER ADAPTOR
1297 Author: Date:
1996 TOYOTA T100 (RM449U)
EXTENSION HOUSING AND TRANSFER ADAPTOR
COMPONENTS