1996 TOYOTA T100 replace manual transmission

Downloaded from www.Manualslib.com manuals search engine MT03T−01
Q00880
3rd
2nd 1st
D00873
3rd
2nd
1st
Q00859
WM0053
MT−22
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of each
gear.
Standard clearance:
0.10 − 0.25 mm (0.0039 − 0.0098 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
2. INSPECT EACH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of each
gear.
Standard clearance:
1st and 2nd gears:
0.009 − 0.060 mm (0.0004 − 0.0024 in.)
3rd gear:
0.015 − 0.066 mm (0.0006 − 0.0026 in.)
Maximum clearance:
1st and 2nd gears:
0.150 mm (0.0059 in.)
3rd gear:
0.200 mm (0.0079 in.)
If the clearance exceeds the maximum, replace the gear, shaft
or needle roller bearing.
3. REMOVE OUTPUT SHAFT CENTER BEARING AND
1ST GEAR ASSEMBLY
(a) Shift the No.1 hub sleeve onto the 2nd gear.
(b) Using a press, remove the center bearing, 1st gear,
needle roller bearing, inner race and synchronizer ring.
4. REMOVE LOCKING BALL ON OUTPUT SHAFT
Using a magnetic finger, remove the locking ball.
5. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 2ND GEAR
AND NEEDLE ROLLER BEARING
Using a press, remove the parts from the shaft as an assembly.

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.

Downloaded from www.Manualslib.com manuals search engine MT0786
WM0066
Q00860
Q00861
Q00862
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−25
1996 TOYOTA T100 (RM449U)
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and the gear spline end.
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
3. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeves and shift forks.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
4. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using vernier calipers, measure the output shaft flange
thickness.
Minimum thickness: 5.60 mm (0.2205 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using vernier calipers, measure the inner race flange
thickness.
Minimum thickness: 4.78 mm (0.1881 in.)
If the thickness is less than the minimum, replace the inner race.
(c) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
2nd gear: 42.975 mm (1.6919 in.)
3rd gear: 31.969 mm (1.2586 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.

Downloaded from www.Manualslib.com manuals search engine Q00863
Q00864
MT−26
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
(d) Using a micrometer, measure the outer diameter of the in-
ner race.
Minimum diameter: 42.975 mm (1.6919 in.)
If the outer diameter is less than the minimum, replace the inner
race.
(e) 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.

Downloaded from www.Manualslib.com manuals search engine MT03Y−01
D00875
D00878
B
A
D00879
Q00914
MT−32
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT COUNTER 5TH GEAR RADIAL CLEAR-
ANCE
(a) Install the spacer, counter 5th gear and needle roller bear-
ing to the counter gear.
(b) Using a dial indicator, measure the counter 5th gear radial
clearance.
Standard clearance:
0.009 − 0.060 mm (0.0004 − 0.0024 in.)
Maximum clearance:
0.150 mm (0.0059 in.)
If the clearance exceeds the maximum, replace the counter
gear, needle roller bearing or counter 5th gear.
2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter
shaft journal.
Minimum diameter:
Part A: 26.975 mm (1.0620 in.)
Part B: 29.950 mm (1.1791 in.)
If the outer race is less than the minimum, replace the counter
gear.
3. INSPECT REVERSE IDLER GEAR RADIAL CLEAR-
ANCE
Using a dial indicator, measure the reverse idler gear radial
clearance.
Standard clearance:
0.041 − 0.074 mm (0.0016 − 0.0029 in.)
Maximum clearance:
0.194 mm (0.0076 in.)
If the clearance exceeds the maximum, replace the gear or
shaft.
4. INSPECT REVERSE IDLER GEAR AND SHIFT ARM
SHOE CLEARANCE
Using a feeler gauge, measure the clearance between the re-
verse idler gear and shift arm shoe.
Standard clearance:
0.20 − 0.41 mm (0.0079 − 0.0161 in.)
Maximum clearance:
0.90 mm (0.0354 in.)
If the clearance exceeds the maximum, replace the shift arm
shoe or reverse idler gear.

Downloaded from www.Manualslib.com manuals search engine Q04038
Q04011
WM0066
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
MT−33
1996 TOYOTA T100 (RM449U)
5. INSPECT 5TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer pull ring, cone ring and outer ring
to the 5th 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.
6. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeves and shift forks.
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 MT03Z−01
WM0073
SST
Q06319
SST
Socket Wrench
RM0013
Socket Wrench
D00876
WM0079
MT−34
− MANUAL TRANSMISSION (W59)COUNTER GEAR AND REVERSE IDLER GEAR
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. IF NECESSARY, REPLACE COUNTER GEAR FRONT
BEARING AND SIDE RACE
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, press out the bearing.
SST 09950−00020
(c) Check the side race for wear or damage.
(d) If necessary, remove the side race.
Using SST and a socket wrench, remove the side race.
SST 09950−40010
(e) Using a socket wrench and press, install a new bearing,
side race and inner race.
(f) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.05 − 2.10 (0.0807 − 0.0827)
B2.10 − 2.15 (0.0827 − 0.0846)
C2.15 − 2.20 (0.0846 − 0.0866)
D2.20 − 2.25 (0.0866 − 0.0886)
E2.25 − 2.30 (0.0886 − 0.0906)
F2.30 − 2.35 (0.0906 − 0.0925)
(g) Using a snap ring expander, install the snap ring.
2. IF NECESSARY, REPLACE COUNTER GEAR CENTER
BEARING
(a) Remove the bearing from the counter gear.
(b) Install a new bearing on the counter gear.
HINT:
Engage the roller cages.

Downloaded from www.Manualslib.com manuals search engine MT042−01
Q07368
SST
− MANUAL TRANSMISSION (W59)FRONT BEARING RETAINER OIL SEAL
MT−39
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 press, install a new oil seal.
SST 09950−60010 (09951−00440), 09950−70010
(09951−07150)
Drive in depth: 12.2 ± 0.5 mm (0.480 ± 0.020 in.)