Output Shaft: Reassembly: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSTALL REVERSE GEAR
1. Coat the reverse gear and No. 1 transmission clutch hub with gear oil.
  
  Fig 1: Identifying Reverse Gear And No. 1 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 synchromesh shifting key springs and 3 synchromesh keys to the No. 1 transmission clutch hub.
3. Install the reverse gear onto the No. 1 transmission clutch hub assembly.
  
  Fig 2: Identifying Reverse Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Position the reverse gear and No. 1 transmission clutch hub correctly as shown in the illustration.
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: Identifying 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 and install it onto the output shaft.
  
  Fig 4: Locating 1St Gear Thrust Washer Of Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR NEEDLE ROLLER BEARING
1. Coat the 1st gear needle roller bearing with gear oil and install it onto the output shaft.
  
  Fig 5: Identifying 1st Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 6: Identifying 1st Gear Cone And No. 1 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the inner ring onto the 1st gear.
3. Install the middle ring onto the 1st gear.
  
  Fig 7: Identifying Middle Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the outer ring onto the 1st gear.
  
  Fig 8: Identifying Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR
1. Coat the 1st gear with gear oil and install it onto the output shaft.
  
  Fig 9: Installing Synchronizer Ring No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 1 TRANSMISSION CLUTCH HUB

Using SST and a press, install the No. 1 transmission clutch hub onto the output shaft.

Fig 10: Installing Transmission Clutch Hub No. 1 Onto Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- 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.

Select a snap ring that will allow minimum axial play.

Fig 11: Installing Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard clearance

0.1 mm (0.00394 in.) or less

Snap Ring Thickness

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)

Using a brass bar and a hammer, install the snap ring onto the output shaft.
NOTE:
Do not damage the output shaft journal surface.

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: Identifying 2nd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 13: Identifying 2nd Gear Cone And No. 2 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the inner ring onto the 2nd gear.
3. Install the middle ring onto the 2nd gear.
  
  Fig 14: Identifying Middle Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the outer ring onto the 2nd gear.
  
  Fig 15: Identifying Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND GEAR
1. Coat the 2nd gear with gear oil and install it onto the output shaft.
  
  Fig 16: Identifying 2nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD DRIVEN GEAR
1. Using SST and a press, install the 3rd driven gear onto the output shaft.
  
  Fig 17: Identifying SST, Press & 3rd Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09316-60011
    - 09316-00031
INSTALL OUTPUT GEAR SPACER
1. Install the output gear spacer onto the output shaft.
  
  Fig 18: Identifying Output Gear Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH DRIVEN GEAR
1. Using SST and a press, install the 4th driven gear onto the output shaft.
  
  Fig 19: Identifying SST, Press & 4th Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09612-22011
INSTALL OUTPUT SHAFT REAR BEARING
1. Using SST and a press, install the output shaft rear bearing onto the output shaft.
  
  Fig 20: Installing Output Shaft Rear Bearing Onto Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09612-22011
INSPECT 2ND GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 2nd gear radial clearance.
  
  Fig 21: Measuring 2nd Gear Radial Clearance Between Gear & Shaft Using Dial Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT 1ST GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 1st gear radial clearance.
  
  Fig 22: Measuring 1st Gear Radial Clearance Between Gear & Shaft Using Dial Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 1st gear, 1st gear needle roller bearing or output shaft.
INSPECT 2ND GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 2nd gear thrust clearance.
  
  Fig 23: Measuring 2Nd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT 1ST GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 1st gear thrust clearance.
  
  Fig 24: Measuring 1St Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.