1996 TOYOTA T100 transmission oil

Downloaded from www.Manualslib.com manuals search engine MT03O−02
− MANUAL TRANSMISSION (W59)MANUAL TRANSMISSION ASSEMBLY
MT−17
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MT−8).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

Downloaded from www.Manualslib.com manuals search engine MT03V−01
Q00888
Z02648
No.2 No.1
Front Front
Q00865
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−27
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 AND NO.2 CLUTCH HUBS INTO HUB
SLEEVE
(a) Install the 3 shifting key springs to the clutch hub.
(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 to
the hub sleeve, as shown.
2. INSTALL 3RD GEAR AND NO.2 CLUTCH HUB ON
OUTPUT SHAFT
(a) Apply gear oil to the shaft.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.

Downloaded from www.Manualslib.com manuals search engine WM0115
Q00887
Q00866
WM0119
MT−28
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
(c) Using a press, install the 3rd gear and No.2 clutch hub.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
C−11.75 − 1.80 (0.0689 − 0.0709)
D1.80 − 1.85 (0.0709 − 0.0728)
111.86 − 1.91 (0.0732 − 0.0752)
121.92 − 1.97 (0.0756 − 0.0776)
131.98 − 2.03 (0.0780 − 0.0799)
142.04 − 2.09 (0.0803 − 0.0823)
152.10 − 2.15 (0.0827 − 0.0846)
(b) Using a snap ring expander, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MT−21)
5. INSTALL 2ND GEAR AND NO.1 CLUTCH HUB
(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 2nd gear.
(d) Using a press, install the 2nd gear and No.1 clutch hub.
6. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MT−21)

Downloaded from www.Manualslib.com manuals search engine Q00868
WM0122
SST
− MANUAL TRANSMISSION (W59)OUTPUT SHAFT
MT−29
1996 TOYOTA T100 (RM449U)
7. INSTALL LOCKING BALL AND 1ST GEAR ASSEMBLY
(a) Install the locking ball in the shaft.
(b) Apply gear oil to the bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller
bearing and bearing inner race.
(d) Install the assembly on the output shaft with the synchro-
nizer ring slots aligned with the shifting keys and turn the
inner race to align it with the locking ball.
8. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a press, install the bearing on the output shaft
with the outer race snap ring groove toward the rear.
SST 09506−35010
HINT:
Hold the 1st gear inner race to prevent it from falling.
9. INSPECT 1ST GEAR THRUST CLEARANCE
(See page MT−21)

Downloaded from www.Manualslib.com manuals search engine MT041−01
WM0295
Front Bearing Retainer
Non −reusable partOil Seal
 MT−38
− MANUAL TRANSMISSION (W59)FRONT BEARING RETAINER OIL SEAL
1337 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BEARING RETAINER OIL SEAL
COMPONENTS

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.)

Downloaded from www.Manualslib.com manuals search engine MT043−03
Z19272
Reverse Restrict PinSlotted Spring PinStraight Screw Plug
Shift Lever Housing
Dust Deflector
Oil Seal
Extension Housing
Snap RingOuter Race Shift and Select Lever
Oil Receiver Pipe
Non−reusable Part
Precoated Part 



 MT−40
− MANUAL TRANSMISSION (W59)EXTENSION HOUSING
1339 Author: Date:
1996 TOYOTA T100 (RM449U)
EXTENSION HOUSING
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Q07370
SST
WM0110
SST
Q07371
SST MT−42
− MANUAL TRANSMISSION (W59)EXTENSION HOUSING
1996 TOYOTA T100 (RM449U)
(c) Using SST, install a new outer race.
SST 09950−60010 (09951−00560), 09950−70010
(09951−07150)
(d) Using a screwdriver, install the snap ring.
3. IF NECESSARY, REPLACE EXTENSION HOUSING
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09308−00010 or 09308−10010 w/ output shaft
installed
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00560), 09950−70010
(09951−07150)
Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)