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Output Shaft: Reassembly

  1. INSTALL REVERSE GEAR 
    1. Coat the reverse gear and No. 1 transmission clutch hub with gear oil.
    2. Install the 3 synchromesh shifting key springs and 3 synchromesh keys to the No. 1 transmission clutch hub.
      Fig 1: Identifying Synchromesh Shifting Key Springs And Synchromesh Keys
      G06012958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the reverse gear onto the No. 1 transmission clutch hub assembly.
      NOTE: Position the reverse gear and No. 1 transmission clutch hub correctly as shown in the illustration.
      Fig 2: Identifying Reverse Gear
      G06012959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL 
    1. Coat the 1st gear thrust washer pin or ball with MP grease and install it onto the output shaft.
      Fig 3: Locating 1St Gear Thrust Washer Pin Or Ball
      G06045343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL 1ST GEAR THRUST WASHER 
    1. Coat the 1st gear thrust washer with gear oil and install it onto the output shaft.
      Fig 4: Locating 1St Gear Thrust Washer
      G04831887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL 1 ST GEAR NEEDLE ROLLER BEARING 
    1. Coat the 1st gear needle roller bearing with gear oil and install it onto the output shaft.
      Fig 5: Locating 1St Gear Needle Roller Bearing
      G04831886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR) 
    1. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
    2. Install the inner ring onto the 1st gear.
      Fig 6: Identifying Inner Ring
      G06012951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the middle ring onto the 1st gear.
      Fig 7: Identifying Middle Ring
      G06012952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the outer ring onto the 1st gear.
      Fig 8: Identifying Outer Ring
      G06012953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL 1ST GEAR 
    1. Coat the 1st gear with gear oil and install it onto the output shaft.
      Fig 9: Installing 1St Gear Onto Output Shaft
      G05194496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NO. 1 TRANSMISSION CLUTCH HUB 
    1. Using SST and a press, install the No. 1 transmission clutch hub onto the output shaft.

      SST 09316-60011 (09316-00031) 

      HINT:

      • Make sure that the 1st gear can be turned.
      • While checking that the 1st gear thrust washer pin or ball is inserted into the groove of the 1st gear thrust washer, press and fit the No. 1 clutch hub.
        Fig 10: Installing No. 1 Transmission Clutch Hub Onto Output Shaft
        G04831907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring that will allow minimum axial play.

      Standard clearance: 

      0.1 mm (0.00394 in.) or less 

      Snap Ring Thickness 

      SNAP RING THICKNESS REFERENCE CHART

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 2.50 (0.0984) D 2.68 (0.1055)
      B 2.56 (0.1008) E 2.74 (0.1079)
      C 2.62(0.1031) F 2.80 (0.1102)
    3. Using a brass bar and a hammer, install the snap ring onto the output shaft.
      Fig 11: Selecting Snap Ring That Will Allow Minimum Axial Play
      G05194498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not damage the output shaft journal surface.
  8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING 
    1. Coat the 2nd gear needle roller bearing and 2nd gear bearing spacer with gear oil, and install them onto the output shaft.
      Fig 12: Locating 2Nd Gear Needle Roller Bearing
      G04831909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 2 SYNCHRONIZER RING SET (FOR 2ND GEAR) 
    1. Coat the 2nd gear cone and No. 2 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
    2. Install the inner ring onto the 2nd gear.
      Fig 13: Identifying Inner Ring
      G06012946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the middle ring onto the 2nd gear.
      Fig 14: Identifying Middle Ring
      G06012947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the outer ring onto the 2nd gear.
      Fig 15: Identifying Outer Ring
      G06012948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL 2ND GEAR 
    1. Coat the 2nd gear with gear oil and install it onto the output shaft.
      Fig 16: Installing 2Nd Gear Onto Output Shaft
      G04831911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL 3RD DRIVEN GEAR 
    1. Using SST and a press, install the 3rd driven gear onto the output shaft.

      SST 09316-60011 (09316-00031) 

      Fig 17: Installing 3Rd Driven Gear Onto Output Shaft
      G04831912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL OUTPUT GEAR SPACER 
    1. Install the output gear spacer onto the output shaft.
      Fig 18: Installing Output Gear Spacer Onto Output Shaft
      G04831879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL 4TH DRIVEN GEAR 
    1. Using SST and a press, install the 4th driven gear onto the output shaft.

      SST 09612-22011 

      Fig 19: Installing 4Th Driven Gear Onto Output Shaft
      G04831914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL OUTPUT SHAFT REAR BEARING 
    1. Using SST and a press, install the output shaft rear bearing onto the output shaft.

      SST 09612-22011 

      Fig 20: Installing Output Shaft Rear Bearing Onto Output Shaft
      G04831915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT 2ND GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear radial clearance.

      Standard clearance: 

      NSK made bearing: 

      0.015 to 0.056 mm (0.000591 to 0.00220 in.) 

      KOYO made bearing: 

      0.015 to 0.058 mm (0.000591 to 0.00228 in.) 

      Maximum clearance: 

      NSK made bearing: 

      0.056 mm (0.00220 in.) 

      KOYO made bearing: 

      0.058 mm (0.00228 in.) 

      If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft.

      Fig 21: Measuring 2Nd Gear Radial Clearance
      G04831877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSPECT 1ST GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 1st gear radial clearance.

      Standard clearance: 

      NSK made bearing: 

      0.015 to 0.056 mm (0.000591 to 0.00220 in.) 

      KOYO made bearing: 

      0.015 to 0.058 mm (0.000591 to 0.00228 in.) 

      Maximum clearance: 

      NSK made bearing: 

      0.056 mm (0.00220 in.) 

      KOYO made bearing: 

      0.058 mm (0.00228 in.) 

      Fig 22: Measuring 1St Gear Radial Clearance
      G04831876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft.

  17. INSPECT 2ND GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear thrust clearance.

      Standard clearance: 

      0.10 to 0.55 mm (0.00394 to 0.0217 in.) 

      Maximum clearance: 

      0.55 mm (0.0217 in.) 

      If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.

      Fig 23: Measuring 2Nd Gear Thrust Clearance
      G04831875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSPECT 1ST GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 1st gear thrust clearance.

      Standard clearance: 

      0.10 to 0.40 mm (0.00394 to 0.0157 in.) 

      Maximum clearance: 

      0.40 mm (0.0157 in.) 

      If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear or No. 1 transmission clutch hub.

      Fig 24: Measuring 1St Gear Thrust Clearance
      G04831874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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