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Output Shaft: Disassembly

  1. INSPECT 1ST GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 1st gear thrust clearance.

      Standard clearance: 

      0.10 to 0.40 mm (0.0039 to 0.0157 in.) 

      Maximum clearance: 

      0.40 mm (0.0157 in.) 

      If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear or No. 1 transmission clutch hub.

      Fig 1: Measuring 1St Gear Thrust Clearance
      G05400698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT 2ND GEAR THRUST CLEARANCE 
    1. Using a dial gauge, measure the 2nd gear thrust clearance.

      Standard clearance: 

      0.10 to 0.55 mm (0.0039 to 0.0217 in.) 

      Maximum clearance: 

      0.55 mm (0.0217 in.) 

      If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.

      Fig 2: Measuring 2Nd Gear Thrust Clearance
      G05400699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT 1ST GEAR RADIAL CLEARANCE 
    1. Using a dial gauge, measure the 1st gear radial clearance between the gear and shaft.

      Standard clearance: 

      KOYO made bearing: 

      0.015 to 0.058 mm (0.0006 to 0.0023 in.) 

      NSK made bearing: 

      0.015 to 0.056 mm (0.0006 to 0.0022 in.) 

      Maximum clearance: 

      KOYO made: 

      0.058 mm (0.0023 in.) 

      NSK made: 

      0.056 mm (0.0022 in.) 

      If the clearance exceeds the maximum, replace the 1st gear or 1st gear needle roller bearing.

      Fig 3: Measuring 1St Gear Radial Clearance Between Gear And Shaft
      G05400700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT 2ND GEAR RADIAL CLEARANCE 
    1. Using a dial gauge, measure the 2nd gear radial clearance between the gear and shaft.

      Standard clearance: 

      KOYO made: 

      0.015 to 0.058 mm (0.0006 to 0.0023 in.) 

      NSK made: 

      0.015 to 0.056 mm (0.0006 to 0.0022 in.) 

      Maximum clearance: 

      KOYO made: 

      0.058 mm (0.0023 in.) 

      NSK made: 

      0.056 mm (0.0022 in.) 

      If the clearance exceeds the maximum, replace the 2nd gear or 2nd gear needle roller bearing.

      Fig 4: Measuring 2Nd Gear Radial Clearance Between Gear And Shaft
      G05400701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE 4TH DRIVEN GEAR 
    1. Using SST and a press, remove the output shaft rear bearing and 4th driven gear from the output shaft.

      SST 09950-00020 

      Fig 5: Removing 4Th Driven Gear
      G05400702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE OUTPUT GEAR SPACER 
    1. Remove the output gear spacer from the output shaft.
      Fig 6: Locating Output Gear Spacer And Output Shaft
      G05400703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE 2ND GEAR 
    1. Using SST and a press, remove the 3rd driven gear with 2nd gear from the output shaft.

      SST 09950-00020 

      Fig 7: Removing 3Rd Driven Gear And 2Nd Gear Output Shaft
      G05400704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE 2ND GEAR NEEDLE ROLLER BEARING 
    1. Remove the 2nd gear needle roller bearing and 2nd gear bearing spacer from the output shaft.
      Fig 8: Locating 2Nd Gear Needle Roller Bearing
      G05400705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 SYNCHRONIZER RING (FOR 2ND GEAR) 
    1. Remove the No. 1 synchronizer ring from the output shaft.
      Fig 9: Identifying No. 1 Synchronizer Ring Of Output Shaft
      G05400706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE 1ST GEAR 
    1. Using 2 screwdrivers and a hammer, remove the clutch hub No. 1 shaft snap ring from the output shaft.

      HINT:

      Use a piece of cloth to keep the shaft snap ring from flying off.

      Fig 10: Identifying Clutch Hub No. 1 Shaft Snap Ring And Output Shaft
      G05400707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the No. 1 clutch hub assembly and 1st gear from the output shaft.

      SST 09950-00020 

      NOTE:
      • Do not tighten SST excessively.
      • Support the input shaft by hand to prevent it from dropping off.
        Fig 11: Identifying No. 1 Clutch Hub Assembly And 1St Gear Of Output Shaft
        G05400708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 1 SYNCHRONIZER RING (FOR 1ST GEAR) 
    1. Remove the No. 1 synchronizer ring from the 1st gear.
      Fig 12: Identifying No. 1 Synchronizer Ring Of 1St Gear
      G05400709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING 
    1. Remove the 1st gear needle roller bearing from the output shaft.
      Fig 13: Locating 1St Gear Needle Roller Bearing Of Output Shaft
      G05400710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE 1ST GEAR THRUST WASHER 
    1. Remove the 1st gear thrust washer from the output shaft.
      Fig 14: Locating 1St Gear Thrust Washer Of Output Shaft
      G05400711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL 
    1. Remove the 1st gear thrust washer pin or ball from the output shaft.
      Fig 15: Locating 1St Gear Thrust Washer Pin Or Ball
      G05400712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REVERSE GEAR 
    1. Remove the reverse gear, 3 synchromesh shifting keys and 3 synchromesh shifting key springs from the No. 1 transmission clutch hub.
      NOTE: Use a piece of cloth to keep the shifting key and shifting key spring from flying off.
      Fig 16: Removing Reverse Gear
      G05400713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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