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Output Shaft ASSY (C59): Overhaul

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

      Standard clearance: 0.10 to 0.40 mm (0.0039 to 0.0157 in.) 

    Fig 1: Measuring Gear Thrust Clearance
    G02614945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT 2nd GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear thrust clearance.

      Standard clearance: 0.10 to 0.45 mm (0.0039 to 0.0177 in.) 

    Fig 2: Measuring Gear Thrust Clearance
    G02614946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT 1st GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 1st gear radial clearance.
    Fig 3: Measuring Gear Radial Clearance
    G02614947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    STANDARD CLEARANCE REFERENCE

    Bearing Clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022)

    If the clearance is out of specification, replace the 1st gear needle roller bearing.

  4. INSPECT 2nd GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear radial clearance.
    Fig 4: Measuring Gear Radial Clearance
    G02614948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    STANDARD CLEARANCE REFERENCE

    Bearing Clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022)

    If the clearance is out of specification, replace the 2nd gear needle roller bearing.

  5. REMOVE 4th DRIVEN GEAR 
    1. Using SST and a press, remove the output shaft rear bearing with 4th driven gear from the output shaft.

      SST 09950-00020

    Fig 5: Removing Output Shaft Rear Bearing
    G02614949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE OUTPUT GEAR SPACER 
    1. Remove the output gear spacer from the output shaft.
    Fig 6: Removing Output Gear Spacer
    G02614950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE 2nd GEAR 
    1. Using SST and a press, remove the 3rd driven gear with 2nd gear from the output shaft.

      SST 09950-00020

    Fig 7: Removing Driven Gear
    G02614951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE 2nd GEAR NEEDLE ROLLER BEARING 
    1. Remove the 2nd gear needle roller bearing and 2nd gear bearing spacer from the output shaft.
    Fig 8: Removing Gear Needle Roller Bearing
    G02614952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE SYNCHRONIZER RING SET NO.2 
    1. Remove the synchronizer ring set No.2 from the output shaft.
    Fig 9: Removing Synchronizer Ring Set
    G02614953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE 1st GEAR 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      Use a shop rag to keep the snap ring from flying.

      Fig 10: Removing Snap Ring
      G02614954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the transmission clutch hub No.1 with 1st gear from the output shaft.

      SST 09950-00020

    NOTE:
    • Do not tighten SST excessively.
    • Support the input shaft by hand so that it will not be dropped off.
    Fig 11: Removing Transmission Clutch Hub
    G02614955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE SYNCHRONIZER RING NO.1 
    1. Remove the synchronizer ring No.1 from the 1st gear.
    Fig 12: Removing Synchronizer Ring
    G02614956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE 1st GEAR NEEDLE ROLLER BEARING 
    1. Remove the 1st gear needle roller bearing from the output shaft.
    Fig 13: Removing 1st Gear Needle Roller Bearing
    G02614957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE 1st GEAR THRUST WASHER 
    1. Remove the 1st gear thrust washer from the output shaft.
    Fig 14: Removing 1st Gear Thrust Washer
    G02614958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE 1st GEAR THRUST WASHER PIN OR BALL 
    1. Remove the 1st gear thrust washer pin or ball from the output shaft.
    Fig 15: Removing 1st Gear Thrust Washer Pin Or Ball
    G02614959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REVERSE GEAR 
    1. Remove the 3 synchromesh shifting keys, 3 synchromesh shifting key springs and reverse gear.

    HINT:

    Use a shop rag to keep the shifting key and shifting key spring from flying.

    Fig 16: Removing Reverse Gear
    G02614960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE OUTPUT SHAFT FRONT BEARING 
    1. Using 2 screwdrivers, remove the snap ring.

      HINT:

      Use a shop rag to keep the snap ring from flying.

    2. Using SST and a press, remove the output shaft front bearing from the output shaft.

      SST 09950-00020

    Fig 17: Removing Output Shaft Front Bearing
    G02614961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT OUTPUT SHAFT 
    1. Using a dial indicator and 2 V-blocks, measure the shaft runout.

      Maximum runout: 0.015 mm (0.0006 in.) 

      If the runout exceeds the maximum, replace the output shaft.

      Fig 18: Measuring Shaft Runout
      G02614962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a micrometer, measure the outer diameter of the output shaft journal surface.

      Outer diameter: Part A: 31.985 mm (1.2592 in.) 

      Part B: 37.985 mm (1.4955 in) 

      Part C: 32.985 mm (1.2986 in) 

    If the outer diameter is below the minimum, replace the output shaft.

    Fig 19: Measuring Outer Diameter Of Output Shaft Journal
    G02614963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSPECT 2nd GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.
    Fig 20: Measuring Inside Diameter
    G02614964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    INSIDE DIAMETER REFERENCE

    New gear: mm (in.) Maximum inside diameter: mm (in.)
    38.015 to 38.031 (1.4967 to 1.4973) 38.031 (1.4973)

    If the inside diameter exceeds the maximum, replace the 2nd gear.

  19. INSPECT 1st GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 1st gear.
    Fig 21: Measuring Inside Diameter Of 1st Gear
    G02614965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    INSIDE DIAMETER REFERENCE

    New gear: mm (in.) Maximum inside diameter: mm (in.)
    44.015 to 44.031 (1.7329 to 1.7335) 44.031 (1.7335)

    If the inside diameter exceeds the maximum, replace the 1st gear.

  20. INSPECT 1st GEAR THRUST WASHER 
    1. Using a micrometer, measure the thickness of 1st gear thrust washer.
    Fig 22: Measuring Thickness Of 1st Gear Thrust Washer
    G02614966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    THICKNESS REFERENCE

    New thrust washer: mm (in.) Minimum thickness: mm (in.)
    5.975 to 6.025 (0.2352 to 0.2372) 5.975 (0.2352)

    If the thickness is below the minimum, replace the 1st gear thrust washer.

  21. INSPECT SYNCHRONIZER RING SET NO.2 
    1. Coat the 2nd gear cone with gear oil.

      Turn the synchronizer ring in one direction while pushing it against the 2nd gear cone. Check that the ring locks.

      If the synchronizer ring does not lock, replace the ring or 2nd gear.

      Fig 23: Inspecting Synchronizer Ring Set
      G02614967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

      Standard clearance: 0.7 to 1.3 mm (0.0276 to 0.0512 In.) 

    If the clearance is out of specification, replace the synchronizer ring set No.2.

    Fig 24: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End.
    G02614968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSPECT SYNCHRONIZER RING NO.1 
    1. Coat the 1st gear cone with gear oil.

      Turn the synchronizer ring in one direction while pushing it against the 1st gear cone. Check that the ring locks.

      If the synchronizer ring does not lock, replace the ring or 1st gear.

      Fig 25: Inspecting Synchronizer Ring
      G02614969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

      Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.065) 

    If the clearance is out of specification, replace the synchronizer ring No.1.

    Fig 26: Measuring Clearance
    G02614970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSPECT REVERSE GEAR 
    1. Using a vernier calipers, measure the width of the reverse gear groove (A) and the thickness of the claw part on the reverse shift fork (B), and calculate the clearance.

      Standard clearance (A - B): 0.15 to 0.35 mm (0.0059 to 0.0138 in.) 

    If the clearance is out of specification, replace the reverse gear and reverse shift fork.

    Fig 27: Measuring Width Of Reverse Gear Groove
    G02614971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSPECT TRANSMISSION CLUTCH HUB NO.1 
    1. Check that the transmission clutch hub No.1 and reverse gear sub-assy slides smoothly.
    2. Check that the spline gear's edges of the reverse gear sub-assy is not worn down.
    Fig 28: Inspecting Transmission Clutch Hub
    G02614972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL REVERSE GEAR 
    1. Coat the reverse gear with gear oil, install it to the transmission clutch hub No.1.
      NOTE: Be sure to set the reverse gear and transmission clutch hub No.1 in incorrect orientation.
    2. Using a screwdriver, install the 3 synchromesh shifting key springs and 3 synchromesh shifting keys.
    Fig 29: Installing Synchromesh Shifting Key Springs
    G02614973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL OUTPUT SHAFT FRONT BEARING 
    1. Using SST and a press, install the new output shaft front bearing (inner race) to the output shaft. SST 09223-50010
      Fig 30: Installing New Output Shaft Front Bearing
      G02614974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring from the table below that will make the thrust clearance of the output shaft front bearing (inner race) below 0.1 mm (0.004 in.).
      SNAP RING THICKNESS REFERENCE

      Part No. Thickness: mm (in.) Mark
      90 90520-30032 1.85 to 1.90 (0.0728 to 0.0748) 7
      90520-30033 1.90 to 1.95 (0.0748 to 0.0768) 8
      90520-30002 1.95 to 2.00 (0.0768 to 0.0787) 1
      90520-30003 2.00 to 2.05 (0.0787 to 0.0807) 2
      90520-30004 2.05 to 2.10 (0.0807 to 0.0827) 3
      90520-30005 2.10 to 2.15 (0.0827 to 0.0846) 4
      90520-30006 2.15 to 2.20 (0.0846 to 0.0866) 5
      90520-30007 2.20 to 2.25 (0.0866 to 0.0886) 6
      Fig 31: Installing Snap Ring
      G02614975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, tap in the snap ring.
    NOTE: Take care not to damage the journal surface of the output shaft.
  27. INSTALL 1st GEAR THRUST WASHER PIN OR BALL 
    1. Coat the 1st gear thrust washer pin or ball with MP grease, install it to the output shaft.
    Fig 32: Installing Gear Thrust Washer Pin Or Ball
    G02614976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL 1st GEAR THRUST WASHER 
    1. Coat the 1st gear thrust washer with gear oil, install it to the output shaft.
    Fig 33: Installing Gear Thrust Washer
    G02614977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL 1st GEAR NEEDLE ROLLER BEARING 
    1. Coat the 1st gear needle roller bearing with gear oil, install it to the output shaft.
    Fig 34: Installing Gear Needle Roller Bearing
    G02614978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL 1st GEAR 
    1. Coat the 1st gear with gear oil, install it to the output shaft.
    Fig 35: Installing 1st Gear
    G02614979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL SYNCHRONIZER RING NO.1 
    1. Coat the synchronizer ring No.1 with gear oil, install it to the 1st gear.
    Fig 36: Installing Synchronizer Ring
    G02614980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL TRANSMISSION CLUTCH HUB NO.1 
    1. Using SST and a press, install the transmission clutch hub No.1 to the output shaft.

      SST 09316-60011 (09316-00031)

      NOTE: The 1st gear can be turned.
      Fig 37: Installing Transmission Clutch Hub
      G02614981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No.1 below 0.1 mm (0.004 in.).
      Fig 38: Installing Snap Ring
      G02614982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS SPECIFICATION

      Part No. Thickness: mm (in.) Mark
      90520-29018 2.50 (0.0984) A
      90520-29019 2.56 (0.1008) B
      90520-29020 2.62 (0.1031) C
      90520-29021 2.68 (0.1055) D
      90520-29022 2.74 (0.1079) E
      90520-29023 2.80 (0.1102) F
    3. Using a brass bar and a hammer, install the snap ring to the output shaft.
    NOTE: Take care not to damage the journal surface of the output shaft.
  33. INSTALL 2nd GEAR NEEDLE ROLLER BEARING 
    1. Coat the 2nd gear needle roller bearing and 2nd gear bearing spacer with gear oil, install them to the output shaft.
    Fig 39: Installing Gear Needle Roller Bearing
    G02614983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL SYNCHRONIZER RING SET NO.2 
    1. Coat the synchronizer ring set No.2 with gear oil, install it to the 2nd gear.
    Fig 40: Installing Synchronizer Ring Set
    G02614984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL 2nd GEAR 
    1. Coat the 2nd gear with gear oil, install it to the output shaft.
    NOTE: Fit the synchronizer inner ring claws into the slots in the transmission clutch hub No.1.
    Fig 41: Installing 2nd Gear
    G02614985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL 3rd DRIVEN GEAR 
    1. Using SST and a press, install the 3rd driven gear to the output shaft.

      SST 09309-36100 (09309-03610), 09608-00071, 09950-60010 (09951-00450)

    Fig 42: Installing Driven Gear To Output Shaft
    G02614986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL OUTPUT GEAR SPACER 
    1. Install the output gear spacer to the output shaft.
    Fig 43: Installing Output Gear Spacer
    G02614987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL 4th DRIVEN GEAR 
    1. Using SST and a press, install 4th driven gear to the output shaft.

      SST 09612-22011

    Fig 44: Installing 4th Driven Gear
    G02614988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL OUTPUT SHAFT REAR BEARING 
    1. Using SST and a press, install output shaft rear bearing to the output shaft.

      SST 09612-22011

    Fig 45: Installing Output Shaft Rear Bearing
    G02614989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSPECT 2nd GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear radial clearance.
    Fig 46: Measuring 2nd Gear Radial Clearance
    G02614990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    STANDARD CLEARANCE REFERENCE

    Bearing Clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022)

    If the clearance is out of specification, replace the 2nd gear needle roller bearing.

  41. INSPECT 1st GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 1st gear radial clearance.
    STANDARD CLEARANCE REFERENCE

    Bearing Clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022)

    If the clearance is out of specification, replace the 1st gear needle roller bearing.

    Fig 47: Measuring 1st Gear Radial Clearance
    G02614991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSPECT 2nd GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear thrust clearance.

      Standard clearance: 0.10 to 0.45 mm (0.0039 to 0.0177 in.) 

    Fig 48: Measuring 2nd Gear Thrust Clearance
    G02614992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSPECT 1st GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 1st gear thrust clearance.

      Standard clearance: 0.10 to 0.40 mm (0.0039 to 0.0157 in.) 

    Fig 49: Measuring 1st Gear Thrust Clearance
    G02614993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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