Output Shaft: Reassembly

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 )
INSTALL REVERSE GEAR
1. Coat the reverse gear with gear oil, install it to the transmission clutch hub No. 1.
  NOTE: Be sure to set the reverse gear and transmission clutch hub No. 1 in incorrect orientation.
2. Using a screwdriver, install the 3 synchromesh shifting key springs and 3 synchromesh shifting keys.
  
  Fig 1: Installing Reverse Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OUTPUT SHAFT FRONT BEARING

Using SST and a press, install the new output shaft front bearing (inner race) to the output shaft.
SST 09223-50010

Fig 2: Installing Output Shaft Front Bearing (Inner Race) To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring from the table below that will make the thrust clearance of the output shaft front bearing (inner race) below 0.1 mm (0.004 in.).

Fig 3: Installing Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Snap ring thickness:

THICKNESS REFERENCE

Part No.	Thickness: mm (in.)	Mark
90520-30032	1.85 to 1.90 (0.0728 to 0.0748)	7
90520-30033	1.90 to 1.95 (0.0748 to 0.0768)	8
90520-30002	1.95 to 2.00 (0.0768 to 0.0787)	1
90520-30003	2.00 to 2.05 (0.0787 to 0.0807)	2
90520-30004	2.05 to 2.10 (0.0807 to 0.0827)	3
90520-30005	2.10 to 2.15 (0.0827 to 0.0846)	4
90520-30006	2.15 to 2.20 (0.0846 to 0.0866)	5
90520-30007	2.20 to 2.25 (0.0866 to 0.0886)	6

Using a brass bar and a hammer, tap in the snap ring.
NOTE: Take care not to damage the journal surface of the output shaft.

INSTALL 1ST GEAR THRUST WASHER PIN OR BALL
1. Coat the 1st gear thrust washer pin or ball with MP grease, install it to the output shaft.
  
  Fig 4: Installing 1St Gear Thrust Washer Pin Or Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR THRUST WASHER
1. Coat the 1st gear thrust washer with gear oil, install it to the output shaft.
  
  Fig 5: Installing 1St Gear Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR NEEDLE ROLLER BEARING
1. Coat the 1st gear needle roller bearing with gear oil, install it to the output shaft.
  
  Fig 6: Locating 1St Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR
1. Coat the 1st gear with gear oil, install it to the output shaft.
  
  Fig 7: Identifying 1St Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING NO. 1
1. Coat the synchronizer ring No. 1 with gear oil, install it to the 1st gear.
  
  Fig 8: Installing Synchronizer Ring No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION CLUTCH HUB NO. 1

Using SST and a press, install the transmission clutch hub No. 1 to the output shaft.
SST 09316-60011 (09316-00031)

NOTE: The 1st gear can be turned.

Fig 9: Installing Transmission Clutch Hub No. 1 To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 1 below 0.1 mm (0.0004 in.)

Snap ring thickness:

THICKNESS REFERENCE

Part No.	Thickness: mm (in.)	Mark
90520-29018	2.50 (0.0984)	A
90520-29019	2.56 (0.1008)	B
90520-29020	2.62(0.1031)	C
90520-29021	2.68 (0.1055)	D
90520-29022	2.74 (0.1079)	E
90520-29023	2.80 (0.1102)	F

Using a brass bar and a hammer, install the snap ring to the output shaft.

Fig 10: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSTALL 2ND GEAR NEEDLE ROLLER BEARING
1. Coat the 2nd gear needle roller bearing and 2nd gear bearing spacer with gear oil, install them to the output shaft.
  
  Fig 11: Installing 2Nd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING SET NO. 2
1. Coat the synchronizer ring set No. 2 with gear oil, install it to the 2nd gear.
  
  Fig 12: Installing Synchronizer Ring Set No.2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND GEAR
1. Coat the 2nd gear with gear oil, install it to the output shaft.
  NOTE: Fit the synchronizer inner ring claws into the slots in the transmission clutch hub No. 1.
  
  Fig 13: Installing 2Nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD DRIVEN GEAR
1. Using SST and a press, install the 3rd driven gear to the output shaft.
  SST 09309-36100 (09309-03610), 09608-00071, 09950-60010 (09951-00450)
  
  Fig 14: Installing 3Rd Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT GEAR SPACER
1. Install the output gear spacer to the output shaft.
  
  Fig 15: Installing Output Gear Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH DRIVEN GEAR
1. Using SST and a press, install 4th driven gear to the output shaft.
  SST 09612-22011
  
  Fig 16: Installing 4Th Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT REAR BEARING
1. Using SST and a press, install output shaft rear bearing to the output shaft.
  SST 09612-22011
  
  Fig 17: Installing Output Shaft Rear Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND GEAR RADIAL CLEARANCE (See INSPECTION )
INSPECT 1ST GEAR RADIAL CLEARANCE (See INSPECTION )
INSPECT 2ND GEAR THRUST CLEARANCE (See INSPECTION )
INSPECT 1ST GEAR THRUST CLEARANCE (See INSPECTION )