Output Shaft: Reassembly

HINT:

Before reassembly, coat all of the sliding and rotating surfaces with gear oil.

1. INSTALL FRONT BEARING INNER RACE 

   Using SST and a press, press in the front bearing inner race.

   SST 09223-50010

   NOTE: Be sure to install the front bearing inner race in the correct direction, as shown in the illustration.
   Fig 1: Pressing Front Bearing Inner Race Using SST

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2. INSTALL SNAP RING 
   1. Select a snap ring from the table below that will make the thrust clearance of the front bearing inner race less than 0.1 mm (0.0039 in.).
      Fig 2: Thickness Specification Chart

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   2. Using a screwdriver and a hammer, tap in the snap ring.
   NOTE: Take care not to damage the journal surface of the output shaft.
   Fig 3: Installing Snap Ring

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3. ASSEMBLE REVERSE GEAR AND NO. 1 CLUTCH HUB 
   1. Install the 3 No. 1 shifting key springs and 3 No. 1 shifting keys to the No. 1 clutch hub.
   2. Install the No. 1 clutch hub to the reverse gear.
   NOTE: Assemble the reverse gear and No. 1 clutch hub in the direction shown in the illustration.
   Fig 4: Installing No. 1 Clutch Hub To Reverse Gear

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4. INSTALL BALL, 1ST GEAR THRUST WASHER, NEEDLE ROLLER BEARING, 1ST GEAR, NO. 1 SYNCHRONIZER RING AND REVERSE GEAR AND NO. 1 CLUTCH HUB ASSEMBLY 
   1. Using a magnetic finger, install the ball to the output shaft.
   2. Fit the 1st gear thrust washer groove securely over the locking ball when installing the thrust washer on the output shaft.
      Fig 5: Installing Ball To Output Shaft

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   3. Apply gear oil to the needle roller bearing and install it.
   4. Install the 1st gear and No. 1 synchronizer ring.
      NOTE: Distinguish the No. 1 synchronizer ring by the teeth on the synchronizer ring.
      Fig 6: Installing Ball, 1St Gear Thrust Washer, Needle Roller Bearing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Place the reverse gear and No. 1 cluck hub assembly and align the No. 1 synchronizer ring slots with the No. 1 shifting keys.
      Fig 7: Placing Reverse Gear And No. 1 Cluck Hub Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   6. Using a press, press in the reverse gear and No. 1 clutch hub assembly.
   NOTE:

   • Be sure to install the reverse gear and No. 1 clutch hub assembly in the correct direction, as shown in the illustration  .
   • When installing, make sure that the ball is placed in a groove of the 1st gear thrust washer  .
   Fig 8: Pressing Reverse Gear And No. 1 Clutch Hub Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL SNAP RING 
   1. Select a snap ring from the table below that will make the thrust clearance of the No. 1 clutch hub less than 0.1 mm (0.004 in.).
      Fig 9: Thickness Specification Chart

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a screwdriver and a hammer, tap in the snap ring.
   Fig 10: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Take care not to damage the journal surface of the output shaft.
6. INSPECT 1ST GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
7. INSTALL SPACER, NEEDLE ROLLER BEARING, NO. 2 SYNCHRONIZER RING, 2ND GEAR AND 3RD DRIVEN GEAR 
   1. Install the spacer.
   2. Apply gear oil to the needle roller bearing and install it.
   3. Place the No. 2 synchronizer ring on the 2nd gear.
      NOTE:

      • Properly fit the synchronizer middle ring claws into the holes in the 2nd gear.
      • Distinguish the No. 2 synchronizer ring by the teeth on the synchronizer ring.
      Fig 11: Placing No. 2 Synchronizer Ring On 2Nd Gear

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   4. Place the 2nd gear with the No. 2 synchronizer ring and align the No. 2 synchronizer ring slots with the No. 1 shifting keys.
      NOTE: Fit the synchronizer inner ring claws into the slots in the No. 1 clutch hub.
      Fig 12: Placing 2Nd Gear With No. 2 Synchronizer Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Using a press, press in the 3rd driven gear.
   NOTE: Be sure to install the 3rd driven gear in the correct direction, as shown in the illustration
8. INSPECT 2ND GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
   Fig 13: Pressing 3Rd Driven Gear

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9. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND REAR RADIAL BALL BEARING 
   1. Install the output gear spacer.
   2. Using SST and a press, press in the 4th driven gear and rear radial ball bearing.

      SST 09608-00071

   NOTE: Be sure to install the 4th driven gear and rear radial ball bearing in the correct direction, as shown in the illustration.

   HINT:

   Set SST to the bearing inner race securely.

   Fig 14: Pressing 4Th Driven Gear And Rear Radial Ball Bearing Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002