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Output Shaft: Disassembly: Disassembly

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  1. INSPECT 1ST GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 1st gear thrust clearance.
      Fig 1: Measuring 1st Gear Thrust Clearance
      GTY159235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard clearance

      0.10 to 0.40 mm (0.00394 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 No. 1 transmission clutch hub.

  2. INSPECT 2ND GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 2nd gear thrust clearance.
      Fig 2: Measuring 2nd Gear Thrust Clearance
      GTY166579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

  3. INSPECT 1ST GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 1st gear radial clearance.
      Fig 3: Measuring 1st Gear Radial Clearance Between Gear And Shaft
      GTY159388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.)

      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.
      Fig 4: Measuring 2nd Gear Radial Clearance Between Gear And Shaft
      GTY159387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.)

      If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output 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.
      Fig 5: Identifying Output Shaft Rear Bearing, 4th Driven Gear And SST
      GTY159236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
  6. REMOVE OUTPUT GEAR SPACER 
    1. Remove the output gear spacer from the output shaft.
      Fig 6: Identifying Output Gear Spacer
      GTY159360Courtesy 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.
      Fig 7: View Of Output Shaft 2nd Gear Removal Procedure
      GTY166845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
  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
      GTY164345Courtesy 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: View Of Output Shaft Synchronizer Ring No. 1
      GTY158803Courtesy 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.
      Fig 10: Identifying Clutch Hub No. 1 Shaft Snap Ring
      GTY159237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

    2. Using SST and a press, remove the No. 1 clutch hub assembly and 1st gear from the output shaft.
      Fig 11: Identifying Clutch Hub No. 1 Assembly And Output Shaft
      GTY165492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
      NOTE:
      • Do not tighten SST excessively.
      • Support the output shaft by hand to prevent it from dropping off.
  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 Of 1st Gear
      GTY158773Courtesy 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
      GTY159361Courtesy 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 Of Output Shaft
      GTY159362Courtesy 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
      GTY166117Courtesy 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.
      Fig 16: View Of Reverse Gear
      GTY162253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Use a piece of cloth to keep the shifting keys and shifting key springs from flying off.

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