Output Shaft: Disassembly

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

INSPECT 1ST GEAR THRUST CLEARANCE (see )INSPECTION
INSPECT 2ND GEAR THRUST CLEARANCE (see )INSPECTION
INSPECT 1st GEAR RADIAL CLEARANCE (see )INSPECTION
INSPECT 2ND GEAR RADIAL CLEARANCE (see )INSPECTION
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 1: Removing 4th Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT GEAR SPACER
1. Remove the output gear spacer from the output shaft.
  
  Fig 2: Locating Output Gear Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 3: Removing 2nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2ND GEAR NEEDLE ROLLER BEARING
1. Remove the 2nd gear needle roller bearing and 2nd gear bearing spacer from the output shaft.
  
  Fig 4: Locating 2nd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SYNCHRONIZER RING SET NO. 2
1. Remove the synchronizer ring set No. 2 from the output shaft.
  
  Fig 5: Identifying Synchronizer Ring Set No.2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Use a shop rag or piece of cloth to keep the snap ring from flying.
  
  Fig 6: Tapping Out Snap Ring
  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
  NOTE:
  - Do not tighten SST excessively.
  - Support the input shaft by hand so that it will not be dropped off.
  Fig 7: Removing Transmission Clutch Hub No. 1 With 1st Gear From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SYNCHRONIZER RING NO. 1
1. Remove the synchronizer ring No. 1 from the 1st gear.
  
  Fig 8: Identifying Synchronizer Ring No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR NEEDLE ROLLER BEARING
1. Remove the 1st gear needle roller bearing from the output shaft.
  
  Fig 9: Removing 1st Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR THRUST WASHER
1. Remove the 1st gear thrust washer from the output shaft.
  
  Fig 10: Removing 1st Gear Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
1. Remove the 1st gear thrust washer pin or ball from the output shaft.
  
  Fig 11: Removing 1st Gear Thrust Washer Pin Or Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE GEAR
1. Remove the 3 synchromesh shifting keys, 3 synchromesh shifting key springs and reverse gear.
  HINT:
  
  Use a shop rag or piece of cloth to keep the shifting key and shifting key spring from flying.
  
  Fig 12: Removing Reverse Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT FRONT BEARING
1. Using 2 screwdrivers, remove the snap ring.
  HINT:
  
  Use a shop rag or piece of cloth 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 13: Removing Output Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OUTPUT SHAFT (see )INSPECTION
INSPECT 2ND GEAR (see )INSPECTION
INSPECT 1ST GEAR (see )INSPECTION
INSPECT 1ST GEAR THRUST WASHER (see )INSPECTION
INSPECT SYNCHRONIZER RING SET NO. 2 (see )INSPECTION
INSPECT SYNCHRONIZER RING NO. 1 (see )INSPECTION
INSPECT REVERSE GEAR (see )INSPECTION
INSPECT TRANSMISSION CLUTCH HUB NO. 1 (see )INSPECTION