Output Shaft: Disassembly

INSPECT 1ST AND 2ND GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.

Standard clearance:

Fig 1: Standard Clearance Specification Chart
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Maximum clearance:

Fig 2: Maximum Clearance Specification Chart
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Fig 3: Measuring Thrust Clearance Using Feeler Gauge
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INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.

Standard clearance:

Fig 4: Standard Clearance Specification Chart
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Maximum clearance:

Fig 5: Maximum Clearance Specification Chart
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Fig 6: Measuring Radial Clearance Between Gear And Shaft
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If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
REMOVE REAR RADIAL BALL BEARING, 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT
1. Using SST and a press, press out the rear radial ball bearing and 4th driven gear.
  SST 09950-00020
  
  HINT:
  
  Support the output shaft assembly by hand so that it will not be dropped off.
2. Remove the output gear spacer.
Fig 7: Pressing Out Rear Radial Ball Bearing And 4Th Driven Gear Using SST
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REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING, SPACER AND NO. 2 SYNCHRONIZER RING
1. Shift the reverse gear into the 1st gear.
  
  Fig 8: Shifting Reverse Gear Into 1St Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press out the 3rd driven gear and 2nd gear.
  SST 09950-00020
  
  HINT:
  
  Support the output shaft assembly by hand so that it will not be dropped off.
3. Remove the needle roller bearing, spacer and No. 2 synchronizer ring.
REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.

NOTE: Take care not to damage the journal surface of the output shaft.

Fig 9: Pressing Out 3Rd Driven Gear And 2Nd Gear Using SST
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REMOVE REVERSE GEAR, NO. 1 CLUTCH HUB ASSEMBLY, NO. 1 SYNCHRONIZER RING, 1ST GEAR, NEEDLE ROLLER BEARING, 1ST GEAR THRUST WASHER AND BALL
1. Using a press, press out the reverse gear, No. 1 clutch hub assembly, No. 1 synchronizer ring and 1st gear.
  HINT:
  
  Support the output shaft assembly by hand so that it will not be dropped off.
2. Remove the needle roller bearing and 1st gear thrust washer.
3. Using a magnetic finger, remove the ball.
REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.

NOTE: Take care not to damage the journal surface of the output shaft.

Fig 10: Pressing Out Reverse Gear, No. 1 Clutch Hub Assembly
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REMOVE FRONT BEARING INNER RACE
Using SST and a press, press out the front bearing inner race.

SST 09950-00020

NOTE: When replacing the front bearing inner race, replace the output shaft front bearing along with it.

HINT:

Support the output shaft by hand so that it will not be dropped off.

Fig 11: Pressing Out Front Bearing Inner Race Using SST
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DISASSEMBLE REVERSE GEAR AND NO. 1 CLUTCH HUB
1. Remove the reverse gear from the No. 1 clutch hub.
2. Remove the 3 No. 1 shifting keys and 3 No. 1 shifting key springs from the No. 1 clutch hub.
Fig 12: Removing Reverse Gear From No. 1 Clutch Hub
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