LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2024 >> Corolla LE >> Repair and Diagnosis >> External Pages >> Different car >> Section 319 (Manual Transaxle System - Service Information (2 Of 2)) >> No. 2 Output Shaft >> Reassembly [09/2022 - ] >> Procedure

Reassembly [09/2022 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota GR Corolla, 2024 Toyota GR Corolla, and 2023 Toyota GR Corolla. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL NEEDLE ROLLER BEARING 
    1. Coat the needle roller bearing with gear oil and install it to the No. 2 output shaft.
      GTY1022034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL REVERSE DRIVEN GEAR 
    1. Coat the reverse driven gear with gear oil and install it to the No. 2 output shaft.
      GTY1022630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 4 TRANSMISSION CLUTCH HUB 
    1. Install the reverse driven gear synchronizer ring, key spring and shifting key to the No. 4 transmission clutch hub.
      GTY1021790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 4 Transmission Hub Sleeve
      *2 Shifting Key
      *3 Reverse Driven Gear Synchronizer Ring
      *4 Key Spring
      *5 No. 4 Transmission Clutch Hub
      *a Claw

      HINT: 

      • Install the shifting key with the grooves on the No. 4 transmission clutch hub side.
      • Install the key spring with the claw on the No. 4 transmission clutch hub side.
      • Refer to the illustration when installing the key spring and shifting key.
    2. Install the No. 4 transmission hub sleeve to the reverse driven gear as shown in the illustration.
    3. Coat the No. 4 transmission clutch hub with gear oil and install it to the No. 2 output shaft.
      GTY1022222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a press, install the reverse driven gear and No. 4 transmission clutch hub to the No. 2 output shaft.
      • SST: 09308-14010 
      NOTE:

      After installation, make sure that the gear and synchronizer ring move smoothly.

      HINT: 

      Make sure that the protruding part on the reverse driven gear synchronizer ring is fitted into the groove of the No. 4 transmission clutch hub.

  4. INSTALL SHAFT SNAP RING 
    1. Select a new shaft snap ring, using the table below, that makes the thrust clearance of the No. 4 transmission clutch hub less than 0.1 mm (0.00394 in.).
      GTY1022645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark
      SHAFT SNAP RING THICKNESS:

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 2.25 to 2.30 (0.0886 to 0.0906) E 2.45 to 2.50 (0.0965 to 0.0984)
      B 2.30 to 2.35 (0.0906 to 0.0925) F 2.50 to 2.55 (0.0984 to 0.1004)
      C 2.35 to 2.40 (0.0925 to 0.0945) G 2.55 to 2.60 (0.1004 to 0.1024)
      D 2.40 to 2.45 (0.0945 to 0.0965) H 2.60 to 2.65 (0.1024 to 0.1043)
    2. Using a brass bar and hammer, tap the shaft snap ring to the No. 2 output shaft.
      GTY1021666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE 

    See step  14

  6. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE 

    See step  15

  7. INSTALL 5TH DRIVEN GEAR 
    1. Install the spacer to the No. 2 output shaft.
      GTY1022048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the needle roller bearing with gear oil and install it to the No. 2 output shaft.
      GTY1022047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the spacer to the No. 2 output shaft.
      GTY1022044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the 5th driven gear with gear oil and install it to the No. 2 output shaft.
      GTY1021834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 3 TRANSMISSION CLUTCH HUB 
    1. Apply gear oil to the No. 3 transmission hub sleeve and No. 3 transmission clutch hub.
      GTY1022287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 3 transmission hub sleeve to the No. 3 transmission clutch hub.
    3. Install the 3 No. 1 synchromesh shifting keys to the No. 3 transmission clutch hub.
    4. Install the 3 synchronizer shifting key springs to the No. 3 transmission clutch hub.
    5. Place the balls in the holes of the No. 1 synchromesh shifting keys and install the No. 3 transmission hub sleeve while pushing in the balls.
      NOTE:

      Take care to prevent the balls from scattering.

    6. Coat the 5th driven gear synchronizer ring with gear oil and install it to the 5th driven gear.
    7. Using SST and a press, install the No. 3 transmission clutch hub to the No. 2 output shaft.
      GTY1022312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-14010 
      NOTE:

      After installation, make sure that the gear and synchronizer ring move smoothly.

      HINT: 

      Make sure that the protruding part on the 5th driven gear synchronizer ring is fitted into the groove of the No. 3 transmission clutch hub.

  9. INSTALL SHAFT SNAP RING 
    1. Select a new shaft snap ring, using the table below, that makes the thrust clearance of the No. 3 transmission clutch hub less than 0.1 mm (0.00394 in.).
      GTY1022613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark
      SHAFT SNAP RING THICKNESS:

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      1 2.25 to 2.30 (0.0886 to 0.0906) 4 2.40 to 2.45 (0.0945 to 0.0965)
      2 2.30 to 2.35 (0.0906 to 0.0925) 5 2.45 to 2.50 (0.0965 to 0.0984)
      3 2.35 to 2.40 (0.0925 to 0.0945) 6 2.50 to 2.55 (0.0984 to 0.1004)
    2. Using a brass bar and hammer, tap the shaft snap ring to the No. 2 output shaft.
      GTY1021649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE 

    See step  10

  11. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE 

    See step  11

  12. INSTALL 6TH DRIVEN GEAR 
    1. Install the spacer to the No. 2 output shaft.
      GTY1021824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the needle roller bearing with gear oil and install it to the No. 2 output shaft.
      GTY1021825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the 6th driven gear synchronizer ring with gear oil and install it to the No. 3 transmission clutch hub.
      GTY1021829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the 6th driven gear with gear oil and install it to the No. 2 output shaft.
      GTY1022285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 2 OUTPUT SHAFT REAR BEARING 
    1. Using SST and a press, install the No. 2 output shaft rear bearing (inner race) to the No. 2 output shaft.
      GTY1021698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09710-04071 
      NOTE:

      After installation, make sure that the gear and synchronizer ring move smoothly.

  14. INSTALL NO. 2 OUTPUT SHAFT BEARING SNAP RING 
    1. Select a new No. 2 output shaft bearing snap ring, using the table below, that makes the thrust clearance of the No. 2 output shaft rear bearing less than 0.1 mm (0.00394 in.).
      GTY1022602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark
      NO. 2 OUTPUT SHAFT BEARING SNAP RING THICKNESS:

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      B 1.85 to 1.90 (0.0728 to 0.0748) 0 2.05 to 2.10 (0.0807 to 0.0827)
      C 1.90 to 1.95 (0.0748 to 0.0768) 1 2.10 to 2.15 (0.0827 to 0.0846)
      D 1.95 to 2.00 (0.0768 to 0.0787) 2 2.15 to 2.20 (0.0846 to 0.0866)
      E 2.00 to 2.05 (0.0787 to 0.0807) - -
    2. Using a snap ring expander, install the No. 2 output shaft bearing snap ring to the No. 2 output shaft.
      GTY1022371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE 

    See step  12

  16. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE 

    See step  13

  17. INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING 
    1. Using SST and a press, install the No. 2 output shaft front bearing (inner race) to the No. 2 output shaft.
      GTY1022138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09309-37010 
      • SST: 09506-30012 
scientia non olet · About LEMON Manuals