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Output Shaft: Disassembly

WARNING: This page is about a different variant/trim than selected.
  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 (0.00394 to 0.0157 in.) 

      Maximum clearance: 

      0.40 mm (0.0157 in.) 

      Fig 1: Measuring 1st Gear Thrust Clearance
      G04831874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  2. INSPECT 2ND GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear thrust clearance.

      Standard clearance: 

      0.10 to 0.55 mm (0.00394 to 0.0217 in.) 

      Maximum clearance: 

      0.55 mm (0.0217 in.) 

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

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

      Standard clearance: 

      NSK made bearing: 

      0.015 to 0.056 mm (0.000591 to 0.00220 in.) 

      KOYO made bearing: 

      0.015 to 0.058 mm (0.000591 to 0.00228 in.) 

      Maximum clearance: 

      NSK made bearing: 

      0.056 mm (0.00220 in.) 

      KOYO made bearing: 

      0.058 mm (0.00228 in.) 

      Fig 3: Measuring 1st Gear Radial Clearance
      G04831876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  4. INSPECT 2ND GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear radial clearance.

      Standard clearance: 

      NSK made bearing: 

      0.015 to 0.056 mm (0.000591 to 0.00220 in.) 

      KOYO made bearing: 

      0.015 to 0.058 mm (0.000591 to 0.00228 in.) 

      Maximum clearance: 

      NSK made bearing: 

      0.056 mm (0.00220 in.) 

      KOYO made bearing: 

      0.058 mm (0.00228 in.) 

      Fig 4: Measuring 2nd Gear Radial Clearance
      G06012928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  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: Removing Output Shaft Rear Bearing
      G04831878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE OUTPUT GEAR SPACER 
    1. Remove the output gear spacer from the output shaft.
      Fig 6: Locating 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 the 2nd gear from the output shaft.

      SST 09950-00020 

      Fig 7: Identifying 3rd Driven Gear With 2nd Gear 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: Locating 2nd Gear Needle Roller Bearing
      G04831881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 2 SYNCHRONIZER RING SET (FOR 2ND GEAR) 
    1. Remove the No. 2 synchronizer ring set from the output shaft.
      Fig 9: Identifying NO. 2 Synchronizer Ring Set (For 2nd Gear)
      G04831882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE 1ST GEAR 
    1. Using 2 screwdrivers and a hammer, remove the No. 1 clutch hub shaft snap ring from the output shaft.

      HINT:

      Use a piece of cloth to keep the shaft snap ring from flying off.

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

      SST 09950-00020 

      NOTE:
      • Do not tighten SST excessively.
      • Support the output shaft by hand to prevent it from dropping off.
      Fig 11: Removing No. 1 Clutch Hub Assembly
      G04831884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR) 
    1. Remove the No. 1 synchronizer ring set from the 1st gear.
      Fig 12: Identifying No. 1 Synchronizer Ring Set
      G05400709Courtesy 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: Locating 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: Locating 1st Gear Thrust Washer
      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: Locating 1st Gear Thrust Washer Pin
      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 the No. 1 transmission clutch hub.
      NOTE: Use a piece of cloth to keep the shifting keys and shifting key springs from flying off.
      Fig 16: Removing Reverse Gear
      G04831889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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