Output Shaft: Disassembly

Using a feeler gauge, measure the thrust clearance of each gear.

1. Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.) 
2. Maximum clearance: 0.25 mm (0.0098 in.) 

Fig 1: Inspecting Each Gear Thrust Clearance

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Using a dial indicator, measure the radial clearance of each gear.

Standard clearance: 

1. 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.) 
2. Maximum clearance: 1st and 2nd gears: 0.060 mm (0.0024 in.) 3rd gear: 0.066 mm (0.0026 in.) 

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

Fig 2: Inspecting Each Gear Radial Clearance

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1. Shift the No. 1 hub sleeve onto the 2nd gear.
2. Using a press, remove the center bearing, 1st gear, needle roller bearing, inner race and synchronizer ring.

Using a magnetic finger, remove the locking ball.

Using a press, remove the parts from the shaft as an assembly.

Fig 4: Removing No. 1 Hub Sleeve Assembly, 2nd Gear & Needle Roller Bearing

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1. Remove the No. 1 hub sleeve from the No. 1 clutch hub.
2. Push the shifting key spring with a screwdriver, remove the 3 shifting keys and key springs.

Fig 5: Removing No. 1 Hub Sleeve, Shifting Key & Spring From No. 1 Clutch Hub

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1. Using a snap ring expander, remove the snap ring.
2. Using a press, remove the No. 2 hub sleeve, synchronizer ring and 3rd gear.

Fig 6: Removing No. 2 Hub Sleeve Assembly & 3rd Gear

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1. Remove the No. 2 hub sleeve from the No. 2 clutch hub.
2. Push the shifting key spring with a screwdriver, remove the 3 shifting keys and key springs.

Fig 7: Removing No. 2 Hub Sleeve, Shifting Key & Spring From No. 2 Clutch Hub

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002