LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2008 >> FJ Cruiser RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 209 (Manual Trans - C50) >> Output Shaft >> Disassembly

Output Shaft: Disassembly

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.
  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.) 

      Maximum clearance: 

      0.40 mm (0.0157 in.) 

      If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear or transmission clutch hub No. 1.

      Fig 1: Measuring 1st Gear Thrust Clearance Using Feeler Gauge
      G04831874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT 2ND GEAR THRUST CLEARANCE 
    1. Using a dial gauge, measure the 2nd gear thrust clearance.

      Standard clearance: 

      0.10 to 0.55 mm (0.0039 to 0.0217 in.) 

      Maximum clearance: 

      0.55 mm (0.0217 in.) 

      If the clearance exceeds the maximum, replace transmission clutch hub No. 1, 2nd gear or 3rd driven gear.

      Fig 2: Measuring 2nd Gear Thrust Clearance Using Dial Gauge
      G04831875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT 1ST GEAR RADIAL CLEARANCE 
    1. Using a dial gauge, measure the 1st gear radial clearance between the gear and shaft.

      Standard clearance: 

      KOYO made bearing: 

      0.015 to 0.058 mm (0.0006 to 0.0023 in.) 

      NSK made bearing: 

      0.015 to 0.056 mm (0.0006 to 0.0022 in.) 

      Maximum clearance: 

      KOYO made: 

      0.058 mm (0.0023 in.) 

      NSK made: 

      0.056 mm (0.0022 in.) 

      If the clearance exceeds the maximum, replace the 1st gear or 1st gear needle roller bearing.

      Fig 3: Measuring 1st Gear Radial Clearance Between Gear & Shaft Using Dial Gauge
      G04831876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT 2ND GEAR RADIAL CLEARANCE 
    1. Using a dial gauge, measure the 2nd gear radial clearance between the gear and shaft.

      Standard clearance: 

      KOYO made: 

      0.015 to 0.058 mm (0.0006 to 0.0023 in.) 

      NSK made: 

      0.015 to 0.056 mm (0.0006 to 0.0022 in.) 

      Maximum clearance: 

      KOYO made: 

      0.058 mm (0.0023 in.) 

      NSK made: 

      0.056 mm (0.0022 in.) 

      If the clearance exceeds the maximum, replace the 2nd gear or 2nd gear needle roller bearing.

      Fig 4: Measuring 2nd Gear Radial Clearance Between Gear & Shaft Using Dial Gauge
      G04831877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE 4TH DRIVEN GEAR 
    1. Using SST and a press, remove the output shaft rear bearing and 4th driven gear from the output shaft.

      SST 09950-00020 

      Fig 5: Identifying SST, Press, Output Shaft Rear Bearing & 4th Driven Gear
      G04831878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE OUTPUT GEAR SPACER 
    1. Remove the output gear spacer from the output shaft.
      Fig 6: Identifying Output Gear Spacer
      G04831879Courtesy 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 2nd Gear From Output Shaft
      G04831880Courtesy 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: Identifying 2nd Gear Needle Roller Bearing
      G04831881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE SYNCHRONIZER RING NO.1 (FOR 2ND GEAR) 
    1. Remove synchronizer ring No. 1 from the output shaft.
      Fig 9: Removing Synchronizer Ring No. 1 From Output Shaft
      G04831882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. 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 or piece of cloth to keep the shaft snap ring from flying off.

      Fig 10: Identifying Screwdrivers, Hammer & Clutch Hub No. 1 Shaft Snap Ring
      G04831883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the clutch hub No. 1 assembly and 1st gear from the output shaft.

      SST 09950-00020 

      NOTE:
      • Do not tighten SST excessively.
      • Support the input shaft by hand to prevent it from dropping off.
        Fig 11: Removing Clutch Hub No. 1 Assembly From Output Shaft
        G04831884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE SYNCHRONIZER RING GEAR NO.1 (FOR 1ST GEAR) 
    1. Remove synchronizer ring No. 1 from the 1st gear.
      Fig 12: Identifying Synchronizer Ring No. 1
      G04831885Courtesy 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: Identifying 1st Gear Needle Roller Bearing
      G04831886Courtesy 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 From Output Shaft
      G04831887Courtesy 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: Identifying 1st Gear Thrust Washer Pin Or Ball
      G04831888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REVERSE GEAR 
    1. Remove the reverse gear, 3 synchromesh shifting keys and 3 synchromesh shifting key springs from transmission clutch hub No. 1.
      NOTE: Use a shop rag or piece of cloth to keep the shifting key and shifting key spring from flying off.
      Fig 16: Identifying Reverse Gear
      G04831889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals