22-manual transmission r150

MT04I–01

–MANUAL TRANSMISSION (R150, R150F) MANUAL TRANSMISSION SYSTEMMT–1

1997 TOYOTA T100 (RM507U)

MANUAL TRANSMISSION SYSTEMPRECAUTIONWhen working with FIPG material, you must observe the following items.� Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-

faces.� Thoroughly clean all components to remove all the loose material.� Clean both sealing surfaces with a non–residue solvent.� Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.� Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must

be removed and reapplied.

MT04J–01

MT–2–MANUAL TRANSMISSION (R150, R150F) TROUBLESHOOTING


TROUBLESHOOTINGPROBLEM SYMPTOMS TABLEUse the table below to help you find the cause of the problem. The numbers indicate the priority of the likelycause of the problem. Check each part in order. If necessary, replace these parts.

Symptom Suspect Area See page

Noise

1. Oil (Level low) 2WD

4WD

2. Oil (Wrong) 2WD

4WD

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

MT–4

MT–8

MT–4

MT–8

MT–12

MT–12

Oil leakage

1. Oil (Level too high) 2WD

4WD

2. Gasket (Damaged)

3. Oil seal (Worn or damaged)

4. O–Ring (Worn or damaged)

MT–4

MT–8

MT–12

MT–12

MT–12

Hard to shift or will not shift

1. Synchronizer ring (Worn or damaged)

2. Shift key spring (Damaged)

MT–23

MT–26

MT–35

MT–26

MT–35

Jumps out of gear

1. Locking ball spring (Damaged)

2. Shift fork (Worn)

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

MT–12

MT–12

MT–12

MT–12

MT04K–01

Q10106

Shift Lever Boot Retainer

Propeller Shaft

Speedometer Cable

Transmission

Engine Rear Mounting

Engine RearMountingBracket

� Gasket

Retainer

Bracket

Front Exhaust Pipe

Back–UpLight SwitchConnector

Transmission Shift Lever

x6

ClutchReleaseCylinder

�

Starter

Rear End Plate

Stabilizer Bar

RetainerCushion

� Non–reusable part

��

�

Retainer

Retainer

Retainer

Retainer

Cushion

Cushion

Cushion

� Gasket

39 (400, 29)

72 (730, 53)36 (370, 27)

74 (750, 54)

65 (660, 48)

58 (590, 43)12 (120, 9)

62 (630, 46)

13 (130, 9)

18 (185, 13)

13 (130, 9)

44 (450, 33)

48 (490, 35)

� 13 (130, 9)

�

12 (120, 9)

58 (590, 43)

13 (130, 9)

18 (180, 13)

N·m (kgf·cm, ft·lbf) : Specified torque

–MANUAL TRANSMISSION (R150, R150F) MANUAL TRANSMISSION UNIT (2WD)MT–3


MANUAL TRANSMISSION UNIT(2WD)COMPONENTS

MT04L–01

MT0501

Down

Cloth Counterclockwise

Q09383

Drain Plug

Filler Plug

Oil Level0–5 mm

Q07197

Q10110

MT–4–MANUAL TRANSMISSION (R150, R150F) MANUAL TRANSMISSION UNIT (2WD)


REMOVAL1. REMOVE TRANSMISSION SHIFT LEVER(a) Remove the 4 screws and shift lever boot retainer.(b) Cover the shift lever cap with a cloth.(c) Pressing down on the shift lever cap and rotate it counter-

clockwise to remove.(d) Pull out the shift lever.HINT:At the time of installation, please refer to the following item.Apply MP grease to the tip of the shift lever.

2. RAISE VEHICLE AND DRAIN TRANSMISSION OILOil grade: API GL–4 or GL–5Viscosity: SAE 75W–90Capacity: 2.6 liters (2.7 US qts, 2.3 Imp. qts)Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

3. REMOVE STABILIZER BAR(See page SA–123)

4. REMOVE PROPELLER SHAFT(See page PR–2)

5. REMOVE FRONT EXHAUST PIPE(a) Disconnect the 2 heated oxygen sensor connectors.(b) Remove the 2 bolts, retainer and gasket.

Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)(c) Remove the 3 bolts and bracket.

Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)(d) Remove the 3 nuts, front exhaust pipe and 2 gaskets.

Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)6. DISCONNECT SPEEDOMETER CABLE AND BACK–

UP LIGHT SWITCH CONNECTOR7. DISCONNECT CLUTCH RELEASE CYLINDERRemove the 4 bolts and release cylinder.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)8. REMOVE STARTER(a) Disconnect the connector and wire from the starter.(b) Remove the 2 bolts and starter.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)9. REMOVE REAR END PLATERemove the 4 bolts and rear end plate.

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

Z18102

A

B

B

BB

A

A

A

Q10111

Q09419

90°

Crossmember



10. JACK UP TRANSMISSION SLIGHTLYUsing a transmission jack, support the transmission.

11. REMOVE ENGINE REAR MOUNTING BRACKETRemove the 8 bolts and engine rear mounting bracket.

Torque:Bolt A: 18 N·m (180 kgf·cm, 13 ft·lbf)Bolt B: 58 N·m (590 kgf·cm, 43 ft·lbf)

12. REMOVE ENGINE REAR MOUNTINGRemove the 4 bolts and engine rear mounting.


13. REMOVE TRANSMISSION(a) Remove the 6 transmission mounting bolts from the en-

gine.Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)

(b) Disconnect the wire harness from the transmission.

(c) Pull out the transmission up and toward the rear.(d) Turn the transmission clockwise.(e) Move the transmission backward again.(f) Lower the front side of the transmission and remove it

from the front side of the vehicle.

MT04M–03



INSTALLATIONInstallation is in the reverse order of removal (See page MT–4).HINT:After installation, do the road test.

MT04N–01

Q10107

Propeller Shaft No.2 Dust Cover

Transmission Shift Lever Knob

Front Console Box

Transfer Shift Lever

Snap Ring

Rear Propeller Shaft

Transmission with Transfer

Clutch Release Cylinder and Line

Engine Rear Mounting

Crossmember

Shift LeverBoot Retainer

TransmissionShift Lever

SpeedometerCable

Front PropellerShaft

x6Starter

Retainer

Collar

Cushion

Bracket

�

Stabilizer Bar


Stiffener Plate (LH)

Oxygen

Retainer

Rear End Plate

Stiffener Plate (RH)

�

�

�

�

Cushion

Cushion

Retainer

Retainer

Front Exhaust Pipe


Propeller Shaft Dust Cover

36 (370, 27)

23 (230, 17)

74 (750, 54)

13 (135, 10)

76 (780, 56)

36 (370, 27)

12 (120, 9)

65 (660, 48)

95 (970, 70)

18 (180,13)

25 (260, 19)

29 (300, 22)

48 (490, 35)

37 (380, 27)

12 (120, 9)

74 (750, 54)

17 (175, 13)39 (400, 29)

72 (730, 53)

39 (400, 29)

37 (380, 27)62 (630, 46)

37 (380, 27)

37 (380, 27)Sensor

76 (780, 56)

� 25 (260, 19)

Transfer Shift LeverKnob

44 (450, 33)



MANUAL TRANSMISSION UNIT(4WD)COMPONENTS

MT04O–01

MT0501

Down

Cloth Counterclockwise

Q08992

Drain Plug

Filler Plug

Oil Level0–5 mm

Q06824



REMOVAL1. REMOVE TRANSMISSION SHIFT LEVER(a) Remove the 4 screws and front console box.(b) Remove the 4 screws and shift lever boot retainer.(c) Cover the shift lever cap with a cloth.(d) Then, pressing down on the shift lever cap, rotate it coun-

terclockwise to remove.(e) Pull out the shift lever.HINT:At the time of installation, please refer to the following item.Apply MP grease to the tip of the shift lever.2. REMOVE TRANSFER SHIFT LEVER

(See page TR–4)

3. RAISE VEHICLE AND DRAIN TRANSMISSION OILOil grade: API GL–4 or GL–5Viscosity: SAE 75W–90Capacity: 2.2 liters (2.3 US qts, 1.9 Imp. qts)Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

4. REMOVE FRONT AND REAR PROPELLER SHAFTS(See page PR–10)

5. DISCONNECT SPEEDOMETER CABLE6. DISCONNECT BACK–UP LIGHT SWITCH AND 4WD

INDICATOR SWITCH CONNECTORS7. DISCONNECT CLUTCH RELEASE CYLINDER AND

LINERemove the 4 bolts, release cylinder and line.


8. REMOVE FRONT EXHAUST PIPE(a) Remove the 2 nuts, gasket and oxygen sensor.(b) Remove the 2 bolts, retainer and gasket.


Q06823

Q06822

Q10111



(c) Remove the 3 bolts and bracket.Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)

(d) Remove the 3 nuts, front exhaust pipe and 2 gaskets.Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)

9. REMOVE STARTER(a) Disconnect the connector and wire from the starter.(b) Remove the 2 bolts and starter.


10. REMOVE STIFFENER PLATE (RH AND LH) ANDREAR END PLATE

Remove the 8 bolts, stiffener plate (RH and LH) and rear endplate.

Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)11. REMOVE STABILIZER BAR

(See page SA–126)12. JACK UP TRANSMISSION SLIGHTLYUsing a transmission jack, support the transmission.13. REMOVE CROSSMEMBER(a) Remove the 4 set bolts of the engine rear mounting.

Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)(b) Remove the 8 bolts and crossmember.


14. REMOVE TRANSMISSION WITH TRANSFER(a) Remove the 6 transmission mounting bolts from the en-

gine.Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)

(b) Disconnect the wire harness from the transmission.(c) Pull out the transmission with the transfer down and to-

ward the rear.15. REMOVE ENGINE REAR MOUNTINGRemove the 4 bolts and engine rear mounting.


Q06907



16. REMOVE TRANSFER FROM TRANSMISSION(a) Remove the transfer adaptor rear mounting bolts.

Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)(b) Pull the transfer straight up and remove it from the trans-

mission.HINT:Take care not to damage the adaptor rear oil seal with the trans-fer input gear spline.HINT:At the time of installation, please refer to the following item.Apply MP grease to the lip of the adaptor oil seal.

MT04P–04



INSTALLATIONInstallation is in the reverse order of removal (See page MT–8).HINT:After installation, do the road test.

MT04Q–01

Q09923

Clutch HousingDrain Plug

Back–Up Light Switch

Filler Plug

Transmission Case

Snap Ring

Front Bearing Retainer

Control ShiftLever Retainer

� Oil Deflector

Restrict Pin

Restrict Pin

Oil Receiver

� Non–reusable part� Precoated part

Oil Receiver Pipe

Extension Housing

Driven Gear

2WD: 4WD:

x9

x8

�

�

Straight Screw Plug

SpringBall

x10

Straight Screw Plugx10

x6

Speedometer

Control ShiftLever Retainer

Transfer Adaptor

�

�

Oil Receiver

19 (190, 14)

44 (450, 32)

37 (380, 27)

36 (370, 27) 17 (170, 12)

18 (185, 13)

37 (380, 27)

19 (190, 14)

�

�

37 (380, 27)

37 (380, 27)

� 19 (190, 14)

37 (380, 27)

Restrict Pin37 (380, 27)

Restrict Pin37 (380, 27)

Straight Screw Plug

� 19 (190, 14)

Straight Screw Plug

� 19 (190, 14)

37 (380, 27)11 (115, 8)

11 (115, 8)


18 (185, 13)

Gasket

Gasket

Gasket

MT–12–MANUAL TRANSMISSION (R150, R150F) MANUAL TRANSMISSION ASSEMBLY


MANUAL TRANSMISSION ASSEMBLYCOMPONENTS

Z15461

Output Shaft AssemblySpeedometer Drive Gear

Snap Ring

Ball

Bearing

Spacer

� Bearing

Input Shaft

Synchronizer Ring

Rear Bearing Retainer

Gear Spline Piece No.5

Synchronizer Cone Ring

Hub Sleeve No.3

Reverse Idler Gear

Shifting Key SpringShaft

Ball

Shifting Key

Counter 5th Gear

Reverse SynchronizerPull Ring

5th Synchronizer Ring

Reverse Synchronizer RingThrust Washer

Counter Gear Rear Bearing

Shift Fork Shaft No.2

Needle Roller Bearing

Straight Pin

Intermediate Plate

Counter Gear

� Front Bearing

Interlock Pin

Straight Pin


Slotted Spring Pin

Shift Fork No.32WD:

2WD:

Shift Fork No.1

Reverse Idler GearMagnet


Shift Lever HousingShift and Select Lever

Shift Lever HousingShift and Select Lever

4WD:

�

Reverse Shift Arm Bracket

Reverse Shift ArmE–Ring

Reverse Shift Fork

Shift Fork ShaftNo.4

N·m (kgf·cm, ft·lbf) : Specified torque� Non–reusable part� Precoated part

� Bearing

Snap Ring

Snap Ring

Snap Ring

Snap Ring

Snap Ring

Snap Ring

Snap Ring

�

�

Spring

18 (185, 13)

38 (390, 28)

18 (185, 13)

20 (200, 14)

Shift Fork No.2

20 (200, 14)

�

38 (390, 28)�

18 (185, 13)

Interlock Pin

Snap Ring

Interlock Pin

Snap Ring

Snap Ring

–MANUAL TRANSMISSION (R150, R150F) MANUAL TRANSMISSION ASSEMBLYMT–13


MT04R–01

Q06902

FIPG



DISASSEMBLY1. REMOVE BACK–UP LIGHT SWITCH

Torque: 44 N·m (450 kgf·cm, 32 ft·lbf)2. 2WD:

REMOVE SPEEDOMETER DRIVEN GEARRemove the driven gear lock plate set bolt and driven gear.

Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)3. REMOVE CLUTCH HOUSING FROM TRANSMISSION

CASERemove the 9 bolts and clutch housing from the transmissioncase.

Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)4. REMOVE CONTROL SHIFT LEVER RETAINER(a) Remove the 6 (2WD) or 4 (4WD) bolts.

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)(b) Remove the retainer and gasket (2WD) or oil deflector

(4WD).5. REMOVE 2 RESTRICT PINS


6. 2WD:REMOVE EXTENSION HOUSING

(a) Remove the shift lever housing set bolt.Torque: 38 N·m (390 kgf·cm, 28 ft·lbf)

(b) Remove the 10 bolts.Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

(c) Using a plastic hammer, tap the extension housing, re-move the shift lever housing and shift and select lever.FIPG:Part No. 08826 – 00090, THREE BOND 1281 orequivalent

Q06901

FIPG

Q06900

FIPG

x8

Q06903

FIPG



7. 4WD:REMOVE TRANSFER ADAPTOR

(a) Remove the shift lever housing set bolt.Torque: 38 N·m (390 kgf·cm, 28 ft·lbf)

(b) Remove the 10 bolts.Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

(c) Using a plastic hammer, tap the transfer adaptor, removethe shift lever housing and the shift and select lever.FIPG:Part No. 08826 – 00090, THREE BOND 1281 orequivalent

8. REMOVE FRONT BEARING RETAINER(a) Remove the 8 bolts.

Sealant:Part No. 08833 – 00080, THREE BOND 1344, LOCTITE242 or equivalentTorque: 17 N·m (170 kgf·cm, 12 ft·lbf)

(b) Using a plastic hammer, tap the front bearing retainer.FIPG:Part No. 08826 – 00090, THREE BOND 1281 orequivalent

9. REMOVE BEARING SNAP RINGUsing a snap ring expander, remove the 2 snap rings.

10. SEPARATE INTERMEDIATE PLATE FROM TRANS-MISSION CASE

(a) Using a brass bar and hammer, carefully tap the transmis-sion case.

(b) Remove the transmission case from the intermediateplate.

HINT:At the time of reassembly, please refer to the following item.Align the each bearing outer race, each fork shaft end and re-verse idler gear shaft end with the case installation holes.

Q06785

Q06905

Q06764



FIPG:Part No. 08826 – 00090, THREE BOND 1281 orequivalent

11. REMOVE MAGNET FROM INTERMEDIATE PLATE

12. MOUNT INTERMEDIATE PLATE IN VISE(a) Use the 2 clutch housing bolts, plate washers and suit-

able nuts, as shown.HINT:Increase or decrease plate washers so that the bolt tip does notprotrude from the nut.(b) Mount the intermediate plate in a vise.

13. REMOVE STRAIGHT SCREW PLUG, LOCKING BALLAND SPRING

(a) Using a hexagon wrench, remove the 4 plugs.Sealant:Part No. 08833 – 00080, THREE BOND 1344, LOCTITE242 or equivalentTorque: 19 N·m (190 kgf·cm, 14 ft·lbf)

(b) Using a magnetic finger, remove the 3 springs and balls.14. REMOVE SHIFT FORK SET BOLTRemove the 2 bolts from the shift forks No.1 and No.2.

Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)15. REMOVE SLOTTED SPRING PINUsing a pin punch and hammer, drive out the pin from the shiftfork No.3.

16. REMOVE SNAP RINGUsing 2 screwdrivers and a hammer, tap out the 4 snap ringsfrom each shift fork shaft.

Q06766

Q06763

Q06768

Q06904

Q06771



17. REMOVE SHIFT FORK SHAFT NO.2 AND SHIFT FORKNO.2

(a) Pull out the shift fork shaft No.2 from the shift forks No.1,No.2 and intermediate plate.

(b) Remove the shift fork No.2 from the groove of hub sleeveNo.2.

(c) Using a magnetic finger, remove the interlock pin from theintermediate plate.


(a) Pull out the shift fork shaft No.1 with the straight pin fromthe shift fork No.1 and intermediate plate.

(b) Remove the shift fork No.1 from the groove of reversegear.



(a) Pull out the shift fork shaft No.3 from the shift fork No.3,reverse shift fork and intermediate plate.

(b) Remove the shift fork No.3 from the groove of hub sleeveNo.3.


20. REMOVE SHIFT FORK SHAFT NO.4(a) Using a magnetic finger, remove the ball.(b) Pull out the shift fork shaft No.4 from the reverse shift fork

and intermediate plate.NOTICE:Take care of the ball in the reverse shift fork. It will springout when you pull out the shift fork shaft No.4.(c) Using a magnetic finger, remove the spring from the re-

verse shift fork.

21. REMOVE REVERSE SHIFT FORK AND ARM(a) Remove the reverse shift fork and arm.HINT:At the time of reassembly, please refer to the following item.Align the reverse shift arm to the pivot of the reverse shift armbracket.(b) Using a screwdriver, remove the E–ring.(c) Separate the reverse shift fork and arm.

RM0063

RM0072



22. REMOVE REVERSE SHIFT ARM BRACKETRemove the 2 bolts and reverse shift arm bracket.


23. 2WD:REMOVE SPEEDOMETER DRIVE GEAR

(a) Using 2 screwdrivers and a hammer, tap out the rear snapring, and remove the drive gear and ball.

(b) Using 2 screwdrivers and a hammer, tap out the frontsnap ring, and remove the drive gear.

24. REMOVE OUTPUT SHAFT REAR BEARING(a) Using 2 screwdrivers and a hammer, tap out the snap

ring.HINT:At the time of reassembly, please refer to the following item.Select a snap ring that allows the minimum axial play.

Mark Thickness mm (in.)

A 2.65 – 2.70 (0.1043 – 0.1063)

B 2.70 – 2.75 (0.1063 – 0.1083)

C 2.75 – 2.80 (0.1083 – 0.1102)

D 2.80 – 2.85 (0.1102 – 0.1122)

E 2.85 – 2.90 (0.1122 – 0.1142)

F 2.90 – 2.95 (0.1142 – 0.1161)

G 2.95 – 3.00 (0.1161 – 0.1181)

H 3.00 – 3.05 (0.1181 – 0.1201)

J 3.05 – 3.10 (0.1201 – 0.1220)

K 3.10 – 3.15 (0.1220 – 0.1240)

L 3.15 – 3.20 (0.1240 – 0.1260)

M 3.20 – 3.25 (0.1260 – 0.1280)

N 3.25 – 3.30 (0.1280 – 0.1299)

P 3.30 – 3.35 (0.1299 – 0.1319)

Q 3.35 – 3.40 (0.1319 – 0.1339)

R 3.40 – 3.45 (0.1339 – 0.1358)

S 3.45 – 3.50 (0.1358 – 0.1378)

Z14821

SST4WD:

Z14820

SST2WD:

RM0070

SST2WD:

RM0071

SST

4WD:

Q06786



(b) Using SST, remove the rear bearing.SST 09950–40010

HINT:At the time of reassembly, please refer to the following items.� 2WD:

Using SST and a hammer, drive in a new bearing.SST 09309–35010

� 4WD:Using SST and a hammer, drive in a new bearing.SST 09316–60011 (09316–00011, 09316–00071)

25. REMOVE SPACER

26. INSPECT COUNTER 5TH GEAR THRUST CLEAR-ANCE

Using a feeler gauge, measure the counter 5th gear thrustclearance.

Standard clearance:0.10 – 0.35 mm (0.0039 – 0.0138 in.)Maximum clearance:0.40 mm (0.0157 in.)

Q06688

Q06605

SST

RM0024

SST



27. REMOVE GEAR SPLINE PIECE NO.5, SYNCHRONIZ-ER RING, NEEDLE ROLLER BEARING AND COUNT-ER 5TH GEAR WITH HUB SLEEVE NO.3

(a) Using 2 screwdrivers and a hammer, tap out the snapring.

HINT:At the time of reassembly, please refer to the following item.Select a snap ring that allows the minimum axial play.


A 2.80 – 2.85 (0.1102 – 0.1122)

B 2.85 – 2.90 (0.1122 – 0.1142)

C 2.90 – 2.95 (0.1142 – 0.1161)

D 2.95 – 3.00 (0.1161 – 0.1181)

E 3.00 – 3.05 (0.1181 – 0.1201)

F 3.05 – 3.10 (0.1201 – 0.1220)

G 3.10 – 3.15 (0.1220 – 0.1240)

(b) Using SST, remove the gear spline piece No.5.SST 09950–50010

(c) Remove the counter 5th gear with the hub sleeve No.3.

HINT:At the time of reassembly, please refer to the following items.� Using SST and a hammer, drive in the gear spline piece

No.5 with the synchronizer ring slots aligned with the shift-ing keys.SST 09316–60011 (09316–00011)

� When installing the gear spline piece No.5, support thecounter gear in front with a 1.4 – 2.3 kg (3 – 5 lb) hammeror equivalent.

28. REMOVE THRUST WASHER AND BALL FROMCOUNTER GEAR

29. REMOVE REAR BEARING RETAINERRemove the 4 bolts and rear bearing retainer.HINT:At the time of reassembly, please refer to the following item.Align the rear bearing retainer to the reverse idler gear shaftgroove.


Z03540

RM0010

Q07393

SST

Q07552

SST SST

25 mm



30. REMOVE REVERSE IDLER GEAR AND SHAFTPull 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

RINGUsing a snap ring expander, remove the snap ring.

32. REMOVE OUTPUT SHAFT AND COUNTER GEARFROM INTERMEDIATE PLATE

(a) Remove the output shaft, counter gear and input shaft asa unit from the intermediate plate by pulling on the countergear and tapping on the intermediate plate with a plastichammer.

(b) Remove the input shaft with the needle roller bearing fromthe 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 DRIVENGEAR 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.)

MT04S–05



REASSEMBLYReassembly is in the reverse order of disassembly (See page MT–14).HINT:Coat all of the sliding and rotating surfaces with gear oil before reassembly.

MT04T–01

WM0301

Snap Ring

� Bearing

Input Shaft

Bearing

Synchronizer Ring


–MANUAL TRANSMISSION (R150, R150F) INPUT SHAFTMT–23


INPUT SHAFTCOMPONENTS

Q00550

MT04U–01

Z03541

MT–24–MANUAL TRANSMISSION (R150, R150F) INPUT SHAFT


INSPECTIONINSPECT 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 pushingit to the gear cone. Check that the ring locks.

If the braking effect is insufficient, apply a small amount of thefine lapping compound between the synchronizer ring and gearcone. Lightly rub the synchronizer ring and gear cone together.NOTICE:Ensure the fine lapping compound is completely washedoff after rubbing.(c) Check again the braking effect of the synchronizer ring.

(d) Using a feeler gauge, measure the clearance betweenthe 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 washedoff after rubbing.

MT04V–01

Z03543

Z03544

SST

Z03545

–MANUAL TRANSMISSION (R150, R150F) INPUT SHAFTMT–25


REPLACEMENTIF NECESSARY, REPLACE INPUT SHAFT BEARING(a) Using a snap ring expander, remove the snap ring.(b) Using a press, remove the bearing.

(c) Using SST and a press, install a new bearing.SST 09506–35010

(d) Select a snap ring that allows minimum axial play.


A 2.10 – 2.15 (0.0827 – 0.0846)

B 2.15 – 2.20 (0.0846 – 0.0866)

C 2.20 – 2.25 (0.0866 – 0.0886)

D 2.25 – 2.30 (0.0886 – 0.0906)

E 2.30 – 2.35 (0.0906 – 0.0925)

F 2.35 – 2.40 (0.0925 – 0.0945)

G 2.40 – 2.45 (0.0945 – 0.0965)

(e) Using a snap ring expander, install the snap ring.

MT04W–01

Q09921

Needle Roller BearingSynchronizer Ring

3rd Gear

Shifting Key Spring

Shifting KeySpring

Hub Sleeve No.2Clutch Hub No.2

Snap Ring

Output Shaft

2WD:

4WD: Output Shaft

Shifting Key Spring


Synchronizer Middle Ring

2nd Gear

Shifting KeyClutch Hub No.1

Synchronizer Ring Straight Pin


5th Gear

CenterBearingThrust

WasherSpacer

1st GearReverseGear

Spacer

Ball

Snap Ring

2WD:Speedometer

� Rear BearingSnap Ring

Rear Bearing Retainer� Non–reusable part

Synchronizer Outer Ring

Synchronizer Inner Ring

Shifting Key

Snap Ring

Snap Ring


Drive Gear18 (185, 13)

MT–26–MANUAL TRANSMISSION (R150, R150F) OUTPUT SHAFT


OUTPUT SHAFTCOMPONENTS

MT04X–01

Q06818

3rd 1st

Z03552

2nd

Z03553

RM0012

–MANUAL TRANSMISSION (R150, R150F) OUTPUT SHAFTMT–27


DISASSEMBLY1. INSPECT EACH GEAR THRUST CLEARANCEMeasure the thrust clearance of each gear.

Standard clearance:1st gear: 0.15 – 0.45 mm (0.0059 – 0.0177 in.)2nd and 3rd gears: 0.10 – 0.25 mm (0.0039 – 0.0098 in.)Maximum clearance:1st gear: 0.50 mm (0.0197 in.)2nd and 3rd gears: 0.30 mm (0.0118 in.)

2. INSPECT EACH GEAR RADIAL CLEARANCEUsing a dial indicator, measure the radial clearance of eachgear.

Standard clearance:1st gear:0.020 – 0.073 mm (0.0008 – 0.0029 in.)2nd and 3rd gears:0.015 – 0.068 mm (0.0006 – 0.0027 in.)Maximum clearance:1st gear: 0.160 mm (0.0063 in.)2nd and 3rd gears: 0.160 mm (0.0063 in.)

If the clearance exceeds the maximum, replace the gear,needle roller bearing or shaft.

3. REMOVE 5TH GEAR, OUTPUT SHAFT CENTERBEARING AND 1ST GEAR ASSEMBLY

(a) Using a press, remove the 5th gear, center bearing, thrustwasher and 1st gear.

(b) Remove the synchronizer ring.(c) Remove the straight pin and needle roller bearing.(d) Remove the spacer.

Z03548

Q00888

Z03550



4. REMOVE REVERSE GEAR ASSEMBLY AND 2NDGEAR ASSEMBLY

(a) Using 2 screwdrivers and a hammer, tap out the snapring.

(b) Using a press, remove the reverse gear assembly and2nd gear assembly.

(c) Remove the needle roller bearing.

5. REMOVE REVERSE GEAR, SHIFTING KEY ANDSPRING FROM CLUTCH HUB NO.1

(a) Remove the reverse gear from the clutch hub No.1.(b) Push the shifting key spring with a screwdriver, remove

the 3 shifting keys and key springs.

6. REMOVE HUB SLEEVE NO.2 ASSEMBLY AND 3RDGEAR ASSEMBLY

(a) Using a snap ring expander, remove the snap ring.(b) Using a press, remove the hub sleeve No.2 assembly and

3rd gear assembly.(c) Remove the needle roller bearing.7. REMOVE SHIFTING KEY AND SPRING FROM HUB

SLEEVE NO.2 ASSEMBLYUsing a screwdriver, remove the 3 shifting keys and 2 springs.

Z03554

MT04Y–01

Z03555

A B C

Z03556

WM0064



INSPECTION1. 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 outputshaft.

(b) Using a micrometer, measure the outer diameter of theoutput 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 SY NCHRONIZERRING

(a) Check for wear or damage.(b) Check the braking effect of the synchronizer ring.

Turn the synchronizer ring in one direction while pushingit to the gear cone. Check that the ring locks.

If the braking effect is insufficient, apply a small amount of thefine lapping compound between the synchronizer ring and gearcone. Lightly rub the synchronizer ring and gear cone together.NOTICE:Ensure the fine lapping compound is completely washedoff after rubbing.(c) Check again the braking effect of the synchronizer ring.

WM0065

Q09913

Q09914

Q09915

WM0066




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 washedoff 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 thesynchronizer ring in one direction while pushing it to thegear cone. Check that the ring locks.

If it does not lock, replace the synchronizer ring.


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 hubsleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)If the clearance exceeds the maximum, replace the shift fork orhub sleeve.

MT04Z–01

Q06699

Front

Q00888

Q06700

Front

Z03558



REASSEMBLYHINT:Coat all of the sliding and rotating surfaces with gear oil beforereassembly.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 notaligned.

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 hubNo.1 to the reverse gear, as shown.

3. INSTALL 3RD GEAR AND HUB SLEEVE NO.2 ONOUTPUT 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.

GM0060

WM0116

RM0023



(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.


A 1.80 – 1.85 (0.0709 – 0.0728)

B 1.85 – 1.90 (0.0728 – 0.0748)

C 1.90 – 1.95 (0.0748 – 0.0768)

D 1.95 – 2.00 (0.0768 – 0.0787)

E 2.00 – 2.05 (0.0787 – 0.0807)

F 2.05 – 2.10 (0.0807 – 0.0827)

G 2.10 – 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–27)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 reversegear assembly.

Z03560

Z03563

Z03564

Z03565

2WD: 4WD:

SST SST



7. INSTALL SNAP RING(a) Select a snap ring that allows the minimum axial play.


A 2.30 – 2.35 (0.0906 – 0.0925)

B 2.35 – 2.40 (0.0925 – 0.0945)

C 2.40 – 2.45 (0.0945 – 0.0965)

D 2.45 – 2.50 (0.0965 – 0.0984)

E 2.50 – 2.55 (0.0984 – 0.1004)

F 2.55 – 2.60 (0.1004 – 0.1024)

G 2.60 – 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 THRUSTWASHER

Install the 1st gear thrust washer onto the output shaft with thestraight 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 theouter race snap ring groove toward the rear.SST 09309–35010

(b) 4WD:Using SST and a hammer, drive in the bearing with theouter race snap ring groove toward the rear.SST 09316–60011 (09316–00011, 09316–00071)

Z03568

SST



11. INSPECT 1ST GEAR THRUST CLEARANCE(See page MT–27)

12. INSPECT 2ND GEAR THRUST CLEARANCE(See page MT–27)

13. INSTALL 5TH GEARUsing SST and a press, install the 5th gear.

SST 09316–60011 (09316–00031)

MT050–01

Z15462

Snap Ring

Counter Gear

Reverse Idler Gear Shaft

� Counter Gear Front Bearing

Reverse Idler Gear

Gear Spline Piece No.5

Synchronizer Cone Ring

Hub Sleeve No.3

Counter 5th Gear


Straight Pin

Thrust Washer

Counter Gear Rear Bearing


Reverse Synchronizer Ring

Shifting KeyShifting Key Spring

5th Synchronizer Ring

Reverse Synchronizer Pull Ring

Snap Ring

–MANUAL TRANSMISSION (R150, R150F) COUNTER GEAR AND REVERSE IDLER GEARMT–35


COUNTER GEAR AND REVERSE IDLER GEARCOMPONENTS

MT051–01

Q07459

Q06828

Q06829

MT–36–MANUAL TRANSMISSION (R150, R150F) COUNTER GEAR AND REVERSE IDLER GEAR


DISASSEMBLYREMOVE HUB SLEEVE NO.3, SHIFTING KEY AND SPRINGFROM SYNCHRONIZER RING(a) Remove the synchronizer ring assembly from the hub

sleeve No.3.(b) Turn the reverse synchronizer pull ring.

(c) Remove the reverse synchronizer ring and 5th synchro-nizer ring from the synchronizer pull ring and cone ring.

(d) Turn the reverse synchronizer pull ring, separate the pullring and cone ring.

(e) Push the shifting key and spring, and remove the 3 shift-ing keys and springs to the reverse synchronizer ring.

MT052–01

Z03569

Q06689

Q06831

Q06832



INSPECTION1. 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 GEARUsing a micrometer, measure the outer diameter of the countergear journal.

Minimum diameter: 27.860 mm (1.0968 in.)If the outer diameter is less than the minimum, replace thecounter 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 thesynchronizer ring in one direction while pushing it to thegear cone. Check that the ring locks.

If it does not lock, replace the synchronizer ring.

WM0066

Q01803

Q06775



4. INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-ANCE

Using a feeler gauge, measure the clearance between the hubsleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)If the clearance exceeds the maximum, replace the shift fork orhub sleeve.

5. INSPECT REVERSE IDLER GEAR RADIAL CLEAR-ANCE

Using a dial indicator, measure the reverse idler gear radialclearance.


If the clearance exceeds the maximum, replace the reverseidler gear or reverse idler gear shaft.6. INSPECT REVERSE IDLER GEAR AND SHIFT ARM

CLEARANCEUsing a feeler gauge, measure the clearance between the re-verse idler gear and shift arm.


If the clearance exceeds the maximum, replace the shift arm orreverse idler gear.

MT053–01

Z03575

SST

RM0013

Socket Wrench

Z03576



REPLACEMENTIF NECESSARY, REPLACE COUNTER GEAR FRONTBEARING(a) Using a snap ring expander, remove the snap ring.(b) Using SST and a press, remove the bearing.

SST 09950–00020(c) Replace the side race.

(d) Using a socket wrench and press, install a new bearingand side race.

(e) Select a snap ring that allows the minimum axial play.


A 2.00 – 2.05 (0.0787 – 0.0807)

B 2.05 – 2.10 (0.0807 – 0.0827)

C 2.10 – 2.15 (0.0827 – 0.0846)

D 2.15 – 2.20 (0.0846 – 0.0866)

E 2.20 – 2.25 (0.0866 – 0.0886)

F 2.25 – 2.30 (0.0886 – 0.0906)

(f) Using a snap ring expander, install the snap ring.

MT054–01

Q06830

Q06828

Q07460

Q06819

Front



REASSEMBLYINSTALL SYNCHRONIZER RING A SSEMBLY TO HUBSLEEVE NO.3(a) Put the key spring to the hole of the shifting key.(b) Push the 3 shifting keys with the 3 key springs to the re-

verse synchronizer ring.(c) Install the synchronizer cone ring to the reverse synchro-

nizer pull ring and turn the pull ring.

(d) Install the 5th synchronizer ring.(e) Install the reverse synchronizer ring.

(f) Turn the reverse synchronizer pull ring.

(g) While pushing the 3 shifting keys, install the synchronizerring assembly to the hub sleeve No.3.

MT055–01

RM0322� Non–reusable part

Front Bearing Retainer

� Oil Seal

–MANUAL TRANSMISSION (R150, R150F) FRONT BEARING RETAINER OIL SEALMT–41


FRONT BEARING RETAINER OIL SEALCOMPONENTS

MT056–01

Z03583

Q07394

SST

MT–42–MANUAL TRANSMISSION (R150, R150F) FRONT BEARING RETAINER OIL SEAL


REPLACEMENTIF NECESSARY, REPLACE FRONT BEARING RETAINEROIL 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

MT058–01

Z16044

4WD:

Slotted Spring Pin

Transfer Adaptor

� Oil Seal

� O–RingDust Deflector

� Oil Seal

Straight Screw Plug�

2WD:

Straight Screw PlugOil Receiver

Reverse Restrict Pin

Oil Receiver PipeOil Receiver

Reverse Restrict Pin

Extension Housing

N·m (kgf·cm, ft·lbf) : Specified torque� Non–reusable part� Precoated part

Slotted Spring Pin

�

11 (115, 8)

19 (190, 14)

19 (190, 14)11 (115, 8)

Straight Screw Plug� 19 (190, 14)

Speedometer Driven Gear

–MANUAL TRANSMISSION (R150, R150F) EXTENSION HOUSING AND TRANSFER ADAPTORMT–43


EXTENSION HOUSING AND TRANSFER ADAPTORCOMPONENTS

MT057–01

Q04410

Z03582

Q07365

SST

MT–44–MANUAL TRANSMISSION (R150, R150F) EXTENSION HOUSING AND TRANSFER ADAPTOR


REPLACEMENT1. IF NECESSARY, REPLACE REVERSE RESTRICT PIN(a) Remove the reverse restrict pin.

(1) Using a torx socket wrench (T40), remove the screwplug.

(2) Using a pin punch and hammer, drive out the slottedspring 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, LOCTITE242 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 HOUSINGOIL 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.

Q07366

SST

–MANUAL TRANSMISSION (R150, R150F) EXTENSION HOUSING AND TRANSFER ADAPTORMT–45


3. 4WD:IF NECESSARY, REPLACE TRANSFER ADAPTOR OILSEAL

(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.)

22-manual transmission r150

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