Output Shaft: Disassembly

INSPECT EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of each gear.
1. Standard clearance: 0.10-0.25 mm (0.0039-0.0098 in.)
2. Maximum clearance: 0.25 mm (0.0098 in.)
Fig 1: Inspecting Each Gear Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EACH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of each gear.
1. Standard clearance:
  1. 1st and 2nd gears: 0.009-0.060 mm (0.0004-0.0024 in.)
  2. 3rd gear: 0.015-0.066 mm (0.0006-0.0026 in.)
2. Maximum clearance:
  1. 1st and 2nd gears: 0.060 mm (0.0024 in.)
  2. 3rd gear: 0.066 mm (0.0026 in.)
If the clearance exceeds the maximum, replace the gear, shaft or needle roller bearing.

Fig 2: Inspecting Each Gear Radial Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT CENTER BEARING AND 1ST GEAR ASSEMBLY
1. Shift the No. 1 hub sleeve onto the 2nd gear.
2. Using a press, remove the center bearing, 1st gear, needle roller bearing, inner race and synchronizer ring.
Fig 3: Removing Output Shaft Center Bearing And 1st Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOCKING BALL ON OUTPUT SHAFT
Using a magnetic finger, remove the locking ball.
REMOVE NO. 1 HUB SLEEVE ASSEMBLY, 2ND GEAR AND NEEDLE ROLLER BEARING
Using a press, remove the parts from the shaft as an assembly.

Fig 4: Removing No. 1 Hub Sleeve Assembly, 2nd Gear And Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 HUB SLEEVE, SHIFTING KEY AND SPRING FROM NO. 1 CLUTCH HUB
1. Remove the No. 1 hub sleeve from the No. 1 clutch hub.
2. Push the shifting key spring with a screwdriver, remove the 3 shifting keys and key springs.
REMOVE NO. 2 HUB SLEEVE ASSEMBLY AND 3RD GEAR
1. Using a snap ring expander, remove the snap ring.
2. Using a press, remove the No. 2 hub sleeve, synchronizer ring and 3rd gear.
REMOVE NO. 2 HUB SLEEVE, SHIFTING KEY AND SPRING FROM NO. 2 CLUTCH HUB
1. Remove the No. 2 hub sleeve from the No. 2 clutch hub.
2. Push the shifting key spring with a screwdriver, remove the 3 shifting keys and key springs.