Output Shaft ASSY (C60): Overhaul

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

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 1st Gear Thrust Clearance
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INSPECT 2nd GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 2nd gear thrust clearance.
  Standard clearance: 0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Fig 2: Measuring 2nd Gear Thrust Clearance
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INSPECT 1st GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 1st gear radial clearance.

Fig 3: Measuring 1st Gear Radial Clearance

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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.

INSPECT 2nd GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 2nd gear radial clearance.

Fig 4: Measuring 2nd Gear Radial Clearance

Courtesy 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.

REMOVE 4th DRIVEN GEAR
1. Using SST and a press, remove the output shaft center bearing with 4th driven gear from the output shaft.
  SST 09950-00020
Fig 5: Removing 4th Driven Gear
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REMOVE OUTPUT GEAR SPACER
1. Remove the output gear spacer from the output shaft.
Fig 6: Removing Output Gear Spacer
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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 2nd Gear
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REMOVE 2nd GEAR NEEDLE ROLLER BEARING
1. Remove the 2nd gear needle roller bearing from the output shaft.
Fig 8: Removing 2nd Gear Needle Roller Bearing
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REMOVE 2nd GEAR BEARING SPACER
1. Remove the 2nd gear bearing spacer from the output shaft.
Fig 9: Removing 2nd Gear Bearing Spacer
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REMOVE SYNCHRONIZER RING SET NO.2
1. Remove the synchronizer ring set No.2 from the output shaft.
Fig 10: Removing Synchronizer Ring Set
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REMOVE 1st GEAR
1. Using 2 screwdrivers and a hammer, remove the clutch hub No.1 shaft snap ring from the output shaft.
  HINT:
  
  Use a shop rag to keep the snap ring from flying.
  
  Fig 11: Removing Clutch Hub
  Courtesy 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
Fig 12: Removing Transmission Clutch Hub
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REMOVE SYNCHRONIZER RING NO.1
1. Remove the synchronizer ring No.1 from the 1st gear.
Fig 13: Removing Synchronizer Ring
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REMOVE 1st GEAR NEEDLE ROLLER BEARING
1. Remove the 1st gear needle roller bearing from the output shaft.
Fig 14: Removing 1st Gear Needle Roller Bearing
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REMOVE 1st GEAR THRUST WASHER
1. Remove the 1st gear thrust washer from the output shaft.
Fig 15: Removing 1st Gear Thrust Washer
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REMOVE 1st GEAR THRUST WASHER PIN OR BALL
1. Remove the 1st gear thrust washer pin or ball from the output shaft.
Fig 16: Removing 1st Gear Thrust Washer Pin Or Ball
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REMOVE OUTPUT SHAFT FRONT BEARING
1. Using 2 screwdrivers, remove the output shaft front bearing 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
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REMOVE REVERSE GEAR
1. Remove the 3 synchromesh shifting keys, 3 synchromesh shifting key springs and reverse gear.
NOTE: Using a shop rag to prevent the synchromesh shifting key and spring from being scattered.

Fig 18: Removing Reverse Gear
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INSPECT OUTPUT SHAFT

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 19: Measuring Shaft Runout
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Using a micrometer, measure the outer diameter of the output shaft journal surface.

OUTER DIAMETER REFERENCE

Part	New shaft: mm (in.)	Minimum outer diameter: mm (in.)
A	31.985 to 32.00 (1.2592 to 1.2598)	31.985 (1.2592)
B	37.985 to 38.000 (1.4955 to 1.4961)	37.985 (1.4955)

If the outer diameter is less than the minimum, replace the output shaft.

Fig 20: Measuring Outer Diameter

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INSPECT 2nd GEAR

Using a cylinder gauge, measure the inside diameter of the 2nd gear.

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.

Fig 21: Measuring Inside Diameter Of 2nd Gear

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INSPECT 1st GEAR

Using a cylinder gauge, measure the inside diameter of the 1st gear.

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.

Fig 22: Measuring Inside Diameter

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INSPECT 1st GEAR THRUST WASHER

Using a micrometer, measure the thickness of 1st gear thrust washer.

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 less than the minimum, replace the 1st gear thrust washer.

Fig 23: Measuring Thickness

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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 24: Inspecting Synchronizer Ring Set
  Courtesy 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)
If the clearance is out of specification, replace the synchronizer ring set No.2.

Fig 25: Measuring Clearance
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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 26: Inspecting Synchronizer Ring
  Courtesy 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 27: Measuring Clearance
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INSPECT REVERSE GEAR
1. Using 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 28: Measuring Width
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INSPECT TRANSMISSION CLUTCH HUB NO.1
1. Check that the transmission clutch hub No.1 and reverse gear slides smoothly.
2. Check that the spline gear's edges of the reverse gear is not worn down.
Fig 29: Inspecting Transmission Clutch Hub
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INSTALL REVERSE GEAR
1. Coat the reverse gear with gear oil, install it to the transmission clutch hub No.1.
  NOTE: Do not 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 30: Installing Synchromesh Shifting Key Springs
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INSTALL OUTPUT SHAFT FRONT BEARING
1. Using SST and a press, install the output shaft front bearing (inner race) to the output shaft.
  SST 09223-50010
2. Using a brass bar and a hammer, install the output shaft snap ring to the output shaft.
Fig 31: Installing Output Shaft Front Bearing
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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 1st Gear Thrust Washer Pin Or Ball
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INSTALL 1st GEAR THRUST WASHER
1. Coat the 1st gear thrust washer with gear oil, install it to the output shaft.
Fig 33: Installing 1st Gear Thrust Washer
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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 1st Gear Needle Roller Bearing
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INSTALL 1st GEAR
1. Coat the 1st gear with gear oil, install it to the output shaft.
Fig 35: Installing 1st Gear
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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
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INSTALL TRANSMISSION CLUTCH HUB NO.1

Using SST and a press, install the transmission clutch hub No.1 to the output shaft.
SST 09309-36100 (09309-03610), 09950-60010 (09951-00450)

NOTE: The 1st gear can be turned.

Fig 37: Installing Transmission Clutch Hub
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Select a snap ring that will allow minimum axial play.

Standard clearance: 0.1 mm (0.004 in.) or less

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

Fig 38: Installing Snap Ring

Using a brass bar and a hammer, install the snap ring to the output shaft.

INSTALL 2nd GEAR BEARING SPACER
1. Coat the 2nd gear bearing spacer with gear oil, install it to the output shaft.
Fig 39: Installing 2nd Gear Bearing Spacer
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INSTALL 2nd GEAR NEEDLE ROLLER BEARING
1. Coat the 2nd gear needle roller bearing with gear oil, install it to the output shaft.
Fig 40: Installing 2nd Gear Needle Roller Bearing
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INSTALL SYNCHRONIZER RING SET NO.2
1. Coat the synchronizer ring set No.2 with gear oil, install it to the 2nd gear.
Fig 41: Installing Synchronizer Ring Set
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INSTALL 2nd GEAR
1. Coat the 2nd gear with oil, install it to the output shaft.
Fig 42: Installing 2nd Gear
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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 43: Installing 3rd Driven Gear
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INSTALL OUTPUT GEAR SPACER
1. Install the output gear spacer to the output shaft.
Fig 44: Installing Output Gear Spacer
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INSTALL 4th DRIVEN GEAR
1. Using SST and a press, install 4th driven gear to the output shaft.
  SST 09612-22011
Fig 45: Installing 4th Driven Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT CENTER BEARING
1. Using SST and a press, install output shaft center bearing to the output shaft.
  SST 09612-22011
Fig 46: Installing Output Shaft Center Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2nd GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 2nd gear radial clearance.

STANDARD CLEARANCE REFERENCE

Bearing	Clearance: mm (in.)
KOYO made	0.015 to 0.058 (0.0006 to 0.0230)
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.

Fig 47: Measuring 2nd Gear Radial Clearance

INSPECT 1st GEAR RADIAL CLEARANCE

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 0.0230)
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 48: Measuring 1st Gear Radial Clearance

INSPECT 2nd GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 2nd gear thrust clearance.
  Standard clearance: 0.10 to 0.55 mm (0.0039 to 0.0217 in.)
Fig 49: Measuring 2nd Gear Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 50: Measuring 1st Gear Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002