Output Shaft: Disassembly

INSPECT 1ST GEAR THRUST CLEARANCE (See INSPECTION )
INSPECT 2ND GEAR THRUST CLEARANCE (See INSPECTION )
INSPECT 1st GEAR RADIAL CLEARANCE (See INSPECTION )
INSPECT 2ND GEAR RADIAL CLEARANCE (See INSPECTION )
REMOVE 4TH DRIVEN GEAR
1. Using SST and a press, remove the output shaft rear bearing with 4th driven gear from the output shaft.
  SST 09950-00020
  
  Fig 1: Removing 4Th Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT GEAR SPACER
1. Remove the output gear spacer from the output shaft.
  
  Fig 2: Removing Output Gear Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2ND GEAR
1. Using SST and a press, remove the 3rd driven gear with 2nd gear from the output shaft.
  SST 09950-00020
  
  Fig 3: Removing 2Nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2ND GEAR NEEDLE ROLLER BEARING
1. Remove the 2nd gear needle roller bearing and 2nd gear bearing spacer from the output shaft.
  
  Fig 4: Removing 2Nd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SYNCHRONIZER RING SET NO. 2
1. Remove the synchronizer ring set No. 2 from the output shaft.
  
  Fig 5: Removing Synchronizer Ring Set No.2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR
1. Using 2 screwdrivers and a hemmer, tap out the snap ring.
  HINT:
  
  Use a shop rag or piece of cloth to keep the snap ring from flying.
  
  Fig 6: Removing 1St Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, remove the transmission clutch hub No. 1 with 1st gear from the output shaft.
  SST 09950-00020
  NOTE:
  - Do not tighten SST excessively.
  - Support the input shaft by hand so that it will not be dropped off.
    
    Fig 7: Removing 1St Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SYNCHRONIZER RING NO. 1
1. Remove the synchronizer ring No. 1 from the 1st gear.
  
  Fig 8: Inspecting Front Differential Pinion Shaft No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR NEEDLE ROLLER BEARING
1. Remove the 1st gear needle roller bearing from the output shaft.
  
  Fig 9: Removing 1St Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR THRUST WASHER
1. Remove the 1st gear thrust washer from the output shaft.
  
  Fig 10: Removing 1St Gear Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
1. Remove the 1st gear thrust washer pin or ball from the output shaft.
  
  Fig 11: Removing 1St Gear Thrust Washer Pin Or Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE GEAR
1. Remove the 3 synchromesh shifting keys, 3 synchromesh shifting key springs and reverse gear.
  HINT:
  
  Use a shop rag or piece of cloth to keep the shifting key and shifting key spring from flying.
  
  Fig 12: Removing Reverse Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT FRONT BEARING
1. Using 2 screwdrivers, remove the snap ring.
  HINT:
  
  Use a shop rag or piece of cloth to keep the snap ring from flying.
2. Using SST and a press, remove the output shaft front bearing from the output shaft.
  SST 09950-00020
  
  Fig 13: Removing Output Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OUTPUT SHAFT (See INSPECTION )
INSPECT 2ND GEAR (See INSPECTION )
INSPECT 1ST GEAR (See INSPECTION )
INSPECT 1ST GEAR THRUST WASHER (See INSPECTION )
INSPECT SYNCHRONIZER RING SET NO. 2 (See INSPECTION )
INSPECT SYNCHRONIZER RING NO. 1 (See INSPECTION )
INSPECT REVERSE GEAR (See INSPECTION )
INSPECT TRANSMISSION CLUTCH HUB NO. 1 (See INSPECTION )