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Output Shaft: Disassembly

  1. MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE 

    Using a feeler gauge, measure the thrust clearance.

    Fig 1: Measuring Thrust Clearance
    G02639867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Maximum clearance: 

    1st gear: 0.40 mm (0.0157 in.) 

    2nd gear: 0.35 mm (0.0138 in.) 

  2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE 

    Using a dial indicator, measure the radial clearance between the gear and shaft.

    Fig 2: Measuring Radial Clearance Between Gear And Shaft
    G02639868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Maximum clearance: 

    1st and 2nd gears: 0.053 mm (0.0021 in.) 

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

  3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH DRIVEN GEAR AND SPACER 
    1. Using a press, remove the bearing and 4th driven gear.
      2. Fig 3: Removing Bearing And 4th Driven Gear
      G02639869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the spacer.
  4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR 

    Using a press, remove the 3rd driven gear and 2nd gear.

    5. Fig 4: Removing 3rd Driven Gear And 2nd Gear
    G02639870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RINGS 
  6. REMOVE INNER RACE AND BALL FROM OUTPUT SHAFT 
  7. REMOVE NO. 1 HUB SLEEVE ASSEMBLY AND 1ST GEAR 

    Using a press, remove the No. 1 hub sleeve and 1st gear.

    8. Fig 5: Removing No. 1 Hub Sleeve & 1st Gear
    G02639871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE SYNCHRONIZER RINGS AND NEEDLE ROLLER BEARING 
  9. REMOVE 1ST GEAR BEARING INNER RACE 

    Using SST and a press, remove the 1st gear bearing inner race.

    SST 09950-00020

    Fig 6: Removing 1st Gear Bearing Inner Race
    G02639872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISASSEMBLY NO. 1 HUB SLEEVE ASSEMBLY 
    1. Remove the No. 1 hub sleeve from the No. 1 clutch hub.
    2. Remove the 3 shifting keys and springs from the No. 1 clutch hub.
      Fig 7: Removing Shifting Keys And Springs From No. 1 Clutch Hub
      G02639873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE OUTPUT SHAFT FRONT BEARING 

    Using SST, remove the output shaft front bearing.

    SST 09950-00020,09950-00030

    Fig 8: Removing Output Shaft Front Bearing
    G02639874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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