Output Shaft: Reassembly

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.

INSTALL REVERSE GEAR
1. Coat the reverse gear with gear oil and install it onto transmission clutch hub No. 1.
  NOTE: Orient the reverse gear and transmission clutch hub No. 1 correctly.
2. Install the 3 synchromesh shifting key springs and 3 synchromesh keys onto transmission clutch hub No. 1.
  
  Fig 1: Installing Reverse Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR THRUST WASHER PIN OR BALL
1. Coat the 1st gear thrust washer pin or ball with MP grease, and install it onto the output shaft.
  
  Fig 2: Identifying 1st Gear Thrust Washer Pin Or Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR THRUST WASHER
1. Coat the 1st gear thrust washer with gear oil and install it onto the output shaft.
  
  Fig 3: Installing 1st Gear Thrust Washer To Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR NEEDLE ROLLER BEARING
1. Coat the 1st gear needle roller bearing with gear oil and install it onto the output shaft.
  
  Fig 4: Identifying 1st Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR
1. Coat the 1st gear with gear oil and install it onto the output shaft.
  
  Fig 5: Identifying 1st Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING NO.1 (FOR 1ST GEAR)
1. Coat synchronizer ring No. 1 with gear oil and install it onto the 1st gear.
  
  Fig 6: Identifying Synchronizer Ring No. 1 (1st Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION CLUTCH HUB NO.1

Using SST and a press, install transmission clutch hub No. 1 onto the output shaft.
SST 09316-60011 (09316-00031)

HINT:
- The 1st gear can be turned.
- While checking that the 1st gear thrust washer pin or ball is inserted into the groove of the 1st gear thrust washer, press and fit the clutch hub No. 1.
  
  Fig 7: Installing Transmission Clutch Hub No. 1 Onto Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring that will allow minimum axial play.

Standard clearance:

0.1 mm (0.039 in.) or less

Snap ring thickness

SNAP RING THICKNESS SPECIFICATION

Mark	Thickness mm (In.)	Mark	Thickness mm (in.)
A	2.50 (0.0984)	D	2.68 (0.1055)
B	2.56 (0.1008)	E	2.74(0.1079)
C	2.62 (0.1031)	F	2.80 (0.1102)

Using a brass bar and a hammer, install the snap ring onto the output shaft.
NOTE: Do not damage the journal surface of the output shaft.

Fig 8: Identifying Brass Bar & Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 2ND GEAR NEEDLE ROLLER BEARING
1. Coat the 2nd gear needle roller bearing and 2nd gear bearing spacer with gear oil, and install them onto the output shaft.
  
  Fig 9: Identifying 2nd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING NO.1 (FOR 2ND GEAR)
1. Coat synchronizer ring No. 1 with gear oil and install it onto the 2nd gear.
  
  Fig 10: Identifying Coat Synchronizer Ring No.1 (2nd Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND GEAR
1. Coat the 2nd gear with gear oil and install it onto the output shaft.
  
  Fig 11: Identifying 2nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD DRIVEN GEAR
1. Using SST and a press, install the 3rd driven gear onto the output shaft.
  SST 09316-60011 (09316-00031)
  
  Fig 12: Identifying SST, Press & 3rd Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT GEAR SPACER
1. Install the output gear spacer onto the output shaft.
  
  Fig 13: Identifying Output Gear Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH DRIVEN GEAR
1. Using SST and a press, install the 4th driven gear onto the output shaft.
  SST 09612-22011
  
  Fig 14: Identifying SST, Press & 4th Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT REAR BEARING
1. Using SST and a press, install the output shaft rear bearing onto the output shaft.
  SST 09612-22011
  
  Fig 15: Identifying SST, Press & Output Shaft Rear Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 0.00023 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 16: Measuring 2nd Gear Radial Clearance Between Gear & Shaft Using Dial Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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:
  
  0.015 to 0.058 mm (0.0006 to 0.00023 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 1st gear or 1st gear needle roller bearing.
  
  Fig 17: Measuring 1st Gear Radial Clearance Between Gear & Shaft Using Dial Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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, the 2nd gear or 3rd driven gear.
  
  Fig 18: Measuring 2nd Gear Thrust Clearance Using Dial Gauge
  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.)
  
  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 19: Measuring 1st Gear Thrust Clearance Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002