Output Shaft: Installation

WARNING: This page is about a different variant/trim than selected.

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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying No. 1 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR NEEDLE ROLLER BEARING
1. Coat the needle roller bearing with gear oil, and install it to the output shaft.
  
  Fig 4: Identifying 1st Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR
1. Coat the 1st gear with gear oil, and install it to the output shaft.
  
  Fig 5: Identifying 1st Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND GEAR BUSH BALL
1. Coat the bush ball with MP grease, and install it to the output shaft.
  
  Fig 7: Locating 2nd Gear Bush Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND GEAR BUSH
1. Coat the bush with gear oil, and install it to the output shaft.
  
  Fig 8: Identifying 2nd Gear Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND GEAR BEARING SPACER
1. Coat the bearing spacer with gear oil, and install it to the output shaft.
  
  Fig 9: Identifying 2nd Gear Bearing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND GEAR NEEDLE ROLLER BEARING
1. Coat the needle roller bearing with gear oil, and install it to the output shaft.
  
  Fig 10: Identifying 2nd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying No. 2 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND GEAR
1. Coat the 2nd gear with gear oil, and install it to the output shaft.
  
  Fig 12: Identifying 2nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT GEAR SPACER
1. Install the output gear spacer to the output shaft.
  
  Fig 14: Identifying Output Gear Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2ND GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance.

Standard clearance

RADIAL CLEARANCE SPECIFICATION

Bearing	Standard clearance
KOYO made	0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made	0.009 to 0.051 mm (0.0004 to 0.0020 in.)

Fig 17: Measuring Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSPECT 1ST GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance.

Standard clearance

RADIAL CLEARANCE SPECIFICATION

Bearing	Standard clearance
KOYO made	0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made	0.009 to 0.051 mm (0.0004 to 0.0020 in.)

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

Fig 18: Measuring 1st Gear Radial Clearance

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: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002