Output Shaft: Disassembly

INSPECT 1ST AND 2ND GEARS THRUST CLEARANCE

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

1ST AND 2ND GEAR - STANDARD CLEARANCE TABLE

1st gear	0.10 to 0.40 mm (0.0039 to 0.0157 in.)
2nd gear	0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

1ST AND 2ND GEAR - MAXIMUM CLEARANCE TABLE

1st gear	0.40 mm (0.0157 in.)
2nd gear	0.55 mm (0.0217 in.)

Fig 1: Measuring Thrust Clearance Using A Feeler Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCE

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

Standard clearance:

1ST AND 2ND GEAR - STANDARD CLEARANCE TABLE

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:

1ST AND 2ND GEAR - MAXIMUM CLEARANCE TABLE

KOYO made	0.058 mm (0.0023 in.)
NSK made	0.056 mm (0.0022 in.)

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

Fig 2: Measuring Radial Clearance Between Gear And 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 3: Removing Rear Radial Ball Bearing And 4th Driven Gear Using SST And A Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 4: 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.

HINT:

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

Fig 5: Removing 3rd Driven Gear And 2nd Gear Using SST And A Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

HINT:

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

Fig 6: Removing Reverse Gear, No. 1 Clutch Hub Assembly, No. 1 Synchronizer Ring And 1st Gear Using A Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 7: Removing Front Bearing Inner Race Using SST And A Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 8: Disassembling Reverse Gear And No. 1 Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002