1996 TOYOTA T100 transmission oil

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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.

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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.)

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MANUAL TRANSMISSION SYSTEM MT-1
TROUBLESHOOTING MT-2
MANUAL TRANSMISSION UNIT MT-3
MANUAL TRANSMISSION ASSEMBLY MT-6
INPUT SHAFT MT-18
OUTPUT SHAFT MT-21
COUNTER GEAR AND REVERSE
IDLER GEAR MT-30
FRONT BEARING RETAINER OIL SEAL MT-38
EXTENSION HOUSING MT-40

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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

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Z15702
Clutch Housing Cover
Snap Ring
Transmission Case
Front Bearing
Clutch HousingFiller Plug Drain Plug Retainer
Release
Fork Support
Straight Screw Plug
Intermediate PlateOutput Shaft
Locking Ball

x 7 x 9
BootBack−Up
Light Switch
Restrict PinControl Shift Lever
Retainer
Oil Baffle Plate
Restrict Pin
Extension Housing Speedometer Driven Gear
Non−reusable part
Precoated partInput Shaft
x 6
x 9Straight Screw Plug
Spring 
 

Gasket
Gasket Gasket
Gasket
Gasket

39 (400, 29)
MT−6
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1305 Author: Date:
1996 TOYOTA T100 (RM449U)
MANUAL TRANSMISSION ASSEMBLY
COMPONENTS

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Q06713
Q06714
FIPG
Q06715
FIPG
x 7 MT−8
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE BACK−UP LIGHT SWITCH
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
2. REMOVE SPEEDOMETER DRIVEN GEAR
Remove the lock plate set bolt and driven gear.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
3. REMOVE CLUTCH HOUSING FROM TRANSMISSION
CASE
Remove the 9 bolts and clutch housing.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE CONTROL SHIFT LEVER RETAINER
(a) Remove the 6 bolts.
Sealant:
Part No.08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Remove the control shift lever retainer and oil baffle plate.
5. REMOVE 2 RESTRICT PINS AND GASKETS
HINT:
At the time of reassembly, please refer to the following item.
Install the black pin on the reverse gear/5th gear side.
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
6. REMOVE EXTENSION HOUSING
(a) Remove the shift lever housing set bolt.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Remove the 9 bolts from the extension housing.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(c) Using a plastic hammer, carefully tap the extension hous-
ing.
(d) Disengage the shift and select lever from the shift head.
(e) Pull out the extension housing.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or equiva-
lent
7. REMOVE FRONT BEARING RETAINER AND BEAR-
ING SNAP RING
(a) Remove the 7 bolts.
Sealant:
Part No.08833 − 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Remove the front bearing retainer.

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Q03881
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−9
1996 TOYOTA T100 (RM449U)
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or equiva-
lent
(c) Using a snap ring expander, remove the 2 bearing snap
rings.
8. SEPARATE INTERMEDIATE PLATE FROM TRANS-
MISSION CASE
(a) Using a plastic hammer, carefully tap the transmission
case.
(b) Pull the transmission case from the intermediate plate.
NOTICE:
At the time of reassembly, please refer to the following
item.
Align each bearing outer race and each shift fork shaft end
with the case holes.
FIPG:
Part No. 08826 − 00090, THREE BOND 1281 or equiva-
lent
9. MOUNT INTERMEDIATE PLATE IN VISE
(a) Use the 2 long clutch housing bolts, plate washers and
suitable nuts, as shown.
HINT:
Increase or decrease plate washers so that the bolt tip does not
protrude from the nut.
(b) Mount the intermediate plate in a vise.
10. REMOVE OIL SEPARATOR
Remove the 2 bolts and oil separator.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
11. REMOVE FRONT MAGNET

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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.)