Adjust Output Shaft Preload

WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

Install the output shaft assembly to the transaxle case.
Install the transmission case to the transaxle case.
HINT:

If necessary, tap on the case with a plastic hammer.
Install and torque the 17 bolts.

Fig 1: Installing & Torquing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque:

29 N.m (300 kgf.cm, 21 ft.lbf) for transaxle case side

30 N.m (306 kgf.cm, 22 ft.lbf) for transmission case side
Install the output shaft rear taper roller bearing outer race.
Install the adjusting shim.
HINT:

When reusing the output shaft bearing, first install a shim of the same thickness as before. If installing a new taper roller bearing, first select and install a shim of lesser thickness than before.
Install the rear bearing retainer.
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
Install a new lock nut to the output shaft.
Turn the output shaft right and left 2 or 3 times to allow the bearing to settle.

Using a torque wrench, measure the preload.

Fig 2: Measuring Preload Using Torque Wrench

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Preload (at starting):

New bearing

0.8 to 1.6 N.m (8 to 16 kgf.cm, 6.9 to 13.9 in.lbf)

Reused bearing

0.5 to 1.0 N.m (5 to 10 kgf.cm, 4.3 to 8.7 in.lbf)

If the preload is not within the specification, select an appropriate adjusting shim.

PRELOAD THICKNESS SPECIFICATION

Mark	Thickness mm (in.)
0	1.30 (0.0512)
1	1.35 (0.0531)
2	1.40 (0.0551)
3	1.45 (0.0571)
4	1.50 (0.0591)
5	1.55 (0.0610)
6	1.60 (0.0630)
7	1.65 (0.0650)
8	1.70 (0.0669)
9	1.75 (0.0689)
A	1.80 (0.0709)
B	1.85 (0.0728)
C	1.90 (0.0748)
D	1.95 (0.0768)
E	2.00 (0.0787)
F	2.05 (0.0807)
G	2.10 (0.0827)
H	2.15 (0.0846)
J	2.20 (0.0866)
K	2.25 (0.0886)
L	2.30 (0.0906)
M	2.35 (0.0925)
N	2.40 (0.0945)
P	2.45 (0.0965)
Q	2.50 (0.0984)

Remove the lock nut.
Remove the 5 parts. Removal is in the reverse order of installation.
1. Remove the rear bearing retainer.
2. Remove the shim.
3. Remove the transmission case.
4. Remove the output shaft assembly.
5. Remove the output shaft rear bearing outer race.