Output Shaft: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

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: Installing Front Bearing Inner Race Using SST And A Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL SNAP RING

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.).

SNAP RING SPECIFICATION TABLE

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
7	1.85(0.0728)	3	2.05(0.0807)
8	1.90(0.0748)	4	2.10(0.0827)
1	1.95(0.0768)	5	2.15(0.0846)
2	2.00(0.0787)	6	2.20(0.0866)

Using a screwdriver and a hammer, tap in the snap ring.

HINT:

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

Fig 2: Installing Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 3: Assembling Reverse Gear And No. 1 Clutch Hub
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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 4: Installing Ball To Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 5: Installing 1st Gear And No. 1 Synchronizer Ring
  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 6: Aligning No. 1 Synchronizer Ring Slots With No. 1 Shifting Keys
  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 7: Installing Reverse Gear And No. 1 Clutch Hub Assembly Using A Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL SNAP RING

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 (0.0039 in.).

SNAP RING SPECIFICATION TABLE

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.50(0.0984)	D	2.68(0.1055)
B	2.56(0.1006)	E	2.74(0.1079)
C	2.62(0.1031)	F	2.80(0.1102)

Using a screwdriver and a hammer, tap in the snap ring.

Fig 8: Installing Snap Ring

HINT:

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

INSPECT 1ST GEAR THRUST CLEARANCE (See DISASSEMBLY )
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 9: Installing Synchronizer Ring And 2nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 10: Fitting Synchronizer Inner Ring Claws Into Clutch Hub Slots
  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.
INSPECT 2ND GEAR THRUST CLEARANCE (See DISASSEMBLY )

Fig 11: Installing 3rd Driven Gear Using A Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 12: Installing 4th Driven Gear And Rear Radial Ball Bearing Using SST And A Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002