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Output Shaft: Installation

WARNING: This page is about a different car, the 2006 Scion tC. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL REVERSE GEAR 
    1. Coat the reverse gear with gear oil.
    2. Install the 3 No. 1 synchromesh shifting key springs and No. 1 transmission clutch hub to the reverse gear.
      NOTE: Assemble the reverse gear and the No. 1 transmission clutch hub in the correct direction.
    3. Using a screwdriver, install the 3 No. 1 synchromesh shifting keys to the reverse gear.
    Fig 1: Installing No. 1 Synchromesh Shifting Keys
    G04222739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT OUTPUT SHAFT BEARING 
    1. Using SST and a press, press in the front bearing (inner race) to the output shaft.

      SST 09950-60010 (09951-00430), 09950-70010 (09951-07150) 

    Fig 2: Pressing In Front Bearing To Output Shaft
    G04222740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 SYNCHRONIZER RING SET 
    1. Coat the No. 1 synchronizer ring set with gear oil, and install it to the 1st gear.
      NOTE: Align the claw of the No. 1 synchronizer ring set (middle) with the hole of the 1st gear and install it.
    Fig 3: Installing No. 1 Synchronizer Ring Set
    G04222741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL 1ST GEAR NEEDLE ROLLER BEARING 
    1. Coat the needle roller bearing with gear oil, and install it to the output shaft.
    Fig 4: Installing 1st Gear Needle Roller Bearing
    G04222742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL 1ST GEAR 
    1. Coat the 1st gear with gear oil, and install it to the output shaft.
    Fig 5: Installing 1st Gear
    G04222743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 TRANSMISSION CLUTCH HUB 
    1. Using SST and a press, press in the No. 1 transmission clutch hub to the output shaft.

      SST 09316-60011 (09316-00031), 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE:
      • Align the claw of the No. 1 synchronizer ring set (outer) with the hole of the No. 1 transmission clutch hub and install it.
      • Make sure that the 1st gear rotates.
    Fig 6: Pressing In No 1 Transmission Clutch Hub To Output Shaft
    G04222744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL 2ND GEAR BUSH BALL 
    1. Coat the bush ball with MP grease, and install it to the output shaft.
    Fig 7: Installing 2nd Gear Bush Ball
    G04222745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL 2ND GEAR BUSH 
    1. Coat the bush with gear oil, and install it to the output shaft.
    Fig 8: Installing 2nd Gear Bush
    G04222746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL 2ND GEAR BEARING SPACER 
    1. Coat the bearing spacer with gear oil, and install it to the output shaft.
    Fig 9: Installing 2nd Gear Bearing Spacer
    G04222747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING 
    1. Coat the needle roller bearing with gear oil, and install it to the output shaft.
    Fig 10: Installing 2nd Gear Needle Roller Bearing
    G04222748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 SYNCHRONIZER RING SET 
    1. Coat the No. 2 synchronizer ring set with gear oil, and install it to the No. 1 transmission clutch hub.
      NOTE: Align the key groove on the No. 2 synchronizer ring set with the No. 1 synchromesh shifting key.
    Fig 11: Installing No. 2 Synchronizer Ring Set
    G04222749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL 2ND GEAR 
    1. Coat the 2nd gear with gear oil, and install it to the output shaft.
    Fig 12: Installing 2nd Gear
    G04222750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL 3RD DRIVEN GEAR 
    1. Using SST and a press, press in the 3rd driven gear to the output shaft.

      SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

    Fig 13: Pressing In 3rd Driven Gear To Output Shaft
    G04222751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL OUTPUT GEAR SPACER 
    1. Install the output gear spacer to the output shaft.
    Fig 14: Installing Output Gear Spacer To Output Shaft
    G04222752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL 4TH DRIVEN GEAR 
    1. Using SST and a press, press in the 4th driven gear to the output shaft.

      SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

    Fig 15: Pressing In 4th Driven Gear To Output Shaft
    G04222753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT OUTPUT SHAFT BEARING 
    1. Using SST and a press, press in the front bearing (inner race) to the output shaft.

      SST 09506-30012, 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

    Fig 16: Pressing In Front Bearing (Inner Race) To Output Shaft
    G04222754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT 2ND GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the radial clearance.

    Standard clearance 

    Bearing Standard clearance
    KOYO made 0.009 to 0.053
    NSK made 0.009 to 0.051

    If the clearance is out of specification, replace the 2nd gear, 2nd gear bush and 2nd gear needle roller bearing.

    Fig 17: Inspecting 2nd Gear Radial Clearance
    G04222755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSPECT 1ST GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the radial clearance.

    Standard clearance 

    Bearing Standard clearance
    KOYO made 0.009 to 0.053
    NSK made 0.009 to 0.051

    If the clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.

    Fig 18: Inspecting 1st Gear Radial Clearance
    G04222756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSPECT 2ND GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance.

      Standard clearance: 

      0.10 to 0.35 mm (0.0039 to 0.0138 in.) 

      If the clearance is out of specification, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.

    Fig 19: Inspecting 2nd Gear Thrust Clearance
    G04222757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT 1ST GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the thrust clearance.

      Standard clearance: 

      0.25 to 0.40 mm (0.0098 to 0.0157 in.) 

      If the clearance is out of specification, replace the 1st gear or No. 1 transmission clutch hub.

    Fig 20: Inspecting 1st Gear Thrust Clearance
    G04222758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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