1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine Q00550
MT04U−01
Z03541
− MANUAL TRANSMISSION (R150, R150F)INPUT SHAFT
MT−23
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: 0.8 mm (0.031 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.

Downloaded from www.Manualslib.com manuals search engine Z03554
MT04Y−05
Z03555
AB
C
Z03556
WM0064
MT−28
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT OUTPUT SHAFT
(a) Using a micrometer, measure the output shaft flange
thickness.
Minimum thickness: 4.70 mm (0.1850 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
A 1st gear: 38.860 mm (1.5299 in.)
B 2nd gear: 46.860 mm (1.8449 in.)
C 3rd gear: 37.860 mm (1.4905 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)
If the runout exceeds the maximum, replace the output shaft.
2. INSPECT 1ST AND 3RD GEARS 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.

Downloaded from www.Manualslib.com manuals search engine WM0065
Q00930
MT0780
D10952
WM0066
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
MT−29
1996 TOYOTA T100 (RM449U)
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 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.
3. INSPECT 2ND GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer inner ring, middle ring and outer
ring to each gear.
(c) 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 it does not lock, replace the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
4. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

Downloaded from www.Manualslib.com manuals search engine MT052−01
Z03569
Q06689
Q06831
Q06832
MT−36
− MANUAL TRANSMISSION (R150, R150F)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Install the spacer, counter 5th gear and needle roller bear-
ings.
(b) Using a dial indicator, measure the counter 5th gear radial
clearance.
Standard clearance:
0.015 − 0.068 mm (0.0006 − 0.0027 in.)
Maximum clearance:
0.160 mm (0.0063 in.)
If the clearance exceeds the maximum, replace the gear bear-
ing or shaft.
2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter
gear journal.
Minimum diameter: 27.860 mm (1.0968 in.)
If the outer diameter is less than the minimum, replace the
counter gear.
3. INSPECT 5TH SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer pull ring, cone ring and outer ring
to the gear spline piece No.5.
(c) 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 it does not lock, replace the synchronizer ring.

Downloaded from www.Manualslib.com manuals search engine MT057−01
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 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 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.

Downloaded from www.Manualslib.com manuals search engine WM0064
MT03U−01
WM0065
Q00930
MT0780
MT−24
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT 1ST GEAR 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.
2. INSPECT 2ND AND 3RD GEAR SYNCHRONIZER
RINGS
(a) Check for wear or damage.
(b) Install the synchronizer inner ring, middle ring and outer
ring to each gear.
(c) 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 it does not lock, replace the synchronizer ring.