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Counter Gear And Reverse Idler Gear: Disassembly

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  1. INSPECT REVERSE GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the reverse gear thrust clearance.

      Standard clearance: 

      0.12 to 0.28 mm (0.0047 to 0.0110 in.) 

      If the clearance is outside the specification, replace the defective gear, spline piece or bearing race.

      Fig 1: Measuring Reverse Gear Thrust Clearance
      G05824840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT 1ST GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 1st gear thrust clearance.

      Standard clearance: 

      0.10 to 0.42 mm (0.0039 to 0.0165 in.) 

      If the clearance is outside the specification, replace the defective gear, clutch hub, spline piece or counter gear.

      Fig 2: Measuring 1st Gear Thrust Clearance
      G05824841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT 2ND GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear thrust clearance.

      Standard clearance: 

      0.10 to 0.42 mm (0.0039 to 0.0165 in) 

      If the clearance is outside the specification, replace the defective gear, clutch hub or counter gear.

      Fig 3: Measuring 2nd Gear Thrust Clearance
      G05824842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT REVERSE GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the reverse gear radial clearance.

      Standard clearance: 

      0.015 to 0.065 mm (0.0006 to 0.0026 in.) 

      If the clearance is outside the specification, replace the reverse gear, reverse gear needle roller bearing or bearing race.

      Fig 4: Measuring Reverse Gear Radial Clearance
      G05824843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT 1ST GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 1st gear radial clearance.

      Standard clearance: 

      0.015 to 0.067 mm (0.0006 to 0.0026 in.) 

      If the clearance is outside the specification, replace the 1st gear, needle roller bearing or shaft.

      Fig 5: Measuring 1st Gear Radial Clearance
      G05824844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT 2ND GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 2nd radial clearance.

      Standard clearance: 

      0.015 to 0.067 mm (0.0006 to 0.0026 in.) 

      If the clearance is outside the specification, replace the 2nd gear, needle roller bearing or shaft.

      Fig 6: Measuring 2nd Gear Radial Clearance
      G05824845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE NO. 1 COUNTER GEAR FRONT BEARING SNAP RING 
    1. Using a snap ring expander, remove the snap ring from the counter gear.
      Fig 7: Removing No. 1 Counter Gear Front Bearing Snap Ring
      G05824846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE COUNTER GEAR FRONT BEARING 
    1. Using SST and a press, remove the counter gear front bearing from the counter gear.

      SST 09950-00020, 09950-70010 (09951 -07100), 09950-60010 (09951-00320) 

      Fig 8: Removing Counter Gear Front Bearing
      G05824847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE REVERSE GEAR BEARING RACE INNER 
    1. Remove the reverse gear bearing race inner from the counter gear.
      Fig 9: Removing Reverse Gear Bearing Race Inner
      G05824848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE COUNTER SHAFT REVERSE GEAR 
    1. Remove the counter shaft reverse gear with the hub sleeve, 2 shifting keys and key spring from the counter gear.
      Fig 10: Removing Counter Shaft Reverse Gear
      G05824849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE REVERSE GEAR NEEDLE ROLLER BEARING 
    1. Remove the reverse gear needle roller bearing from the counter gear.
      Fig 11: Removing Reverse Gear Needle Roller Bearing
      G05824850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 4 SYNCHRONIZER RING 
    1. Remove the No. 4 synchronizer ring from the counter gear.
      Fig 12: Removing No. 4 Synchronizer Ring
      G05824851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE DETENT BALL 
    1. Remove the ball from the counter gear.
      Fig 13: Removing Ball From Counter Gear
      G05824852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE COUNTER SHAFT GEAR 1ST SPEED 
    1. Using a press, remove the counter shaft gear 1st speed together with reverse gear spline piece from the counter gear.

      SST 09950-00020 

      Fig 14: Removing Counter Shaft Gear 1st Speed
      G05824853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING 
    1. Remove the 1st gear needle roller bearing from the counter gear.
      Fig 15: Removing 1st Gear Needle Roller Bearing
      G05824854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 1 SYNCHRONIZER RING SET (for 1st Gear) 
    1. Remove the No. 1 synchronizer ring set from the counter gear.
      Fig 16: Removing No. 1 Synchronizer Ring Set From Counter Gear
      G05824855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE CLUTCH HUB NO. 1 SHAFT SNAP RING 
    1. Using a snap ring expander, remove the snap ring from the counter gear.
      Fig 17: Removing Clutch Hub No. 1 Shaft Snap Ring
      G05824856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE COUNTER SHAFT 2ND SPEED GEAR 
    1. Using a press, remove the counter shaft 2nd speed gear together with the No. 1 transmission clutch hub from the counter gear.

      SST 09950-00020 

      Fig 18: Removing Counter Shaft 2nd Speed Gear
      G05824857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE 2ND GEAR NEEDLE ROLLER BEARING 
    1. Remove the 2nd needle roller bearing from the counter gear.
      Fig 19: Removing 2nd Gear Needle Roller Bearing
      G05824858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 1 SYNCHRONIZER RING SET (for 2nd Gear) 
    1. Remove the No. 1 synchronizer ring set from the 2nd gear.
      Fig 20: Removing No. 1 Synchronizer Ring Set From 2nd Gear
      G05824859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 1 TRANSMISSION CLUTCH HUB 
    1. Remove the hub sleeve, 3 synchromesh shifting keys, 3 balls and 3 springs from the clutch hub.

      HINT:

      Use a shop rag or a piece of cloth to prevent the ball and spring from flying off.

      Fig 21: Removing No. 1 Transmission Clutch Hub
      G05824860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE SNAP RING COUNTER GEAR REAR BEARING 
    1. Using a snap ring expander, remove the snap ring from the counter gear.
      Fig 22: Removing Snap Ring Counter Gear Rear Bearing
      G05824861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE RADIAL BALL BEARING INNER RACE 
    1. Using SST and a press, remove the needle roller bearing inner race.

      SST 09950-00020 

      Fig 23: Removing Radial Ball Bearing Inner Race
      G05824862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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