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Reassembly [09/2022 - ]: Procedure

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  1. INSTALL OUTPUT SHAFT FRONT BEARING INNER RACE 
    1. Using SST and a press, install the output shaft front bearing inner race to the No. 1 output shaft.
      GTY1118972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09710-30012 
        1. 09710-04091
  2. INSTALL 1ST DRIVEN GEAR 
    1. Coat the needle roller bearing with gear oil and install it to the No. 1 output shaft.
      GTY1021711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the inner ring to the 1st driven gear.
      GTY1021881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inner Ring
    3. Install the middle ring to the 1st driven gear.
      GTY1022545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Middle Ring
    4. Install the outer ring to the 1st driven gear.
      GTY1021670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Outer Ring
    5. Coat the 1st driven gear with gear oil and install it to the No. 1 output shaft.
      GTY1022608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 TRANSMISSION CLUTCH HUB 
    1. Apply gear oil to the No. 1 transmission hub sleeve and No. 1 transmission clutch hub.
      GTY1023313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 transmission hub sleeve to the No. 1 transmission clutch hub.
    3. Install the 3 No. 1 synchromesh shifting keys to the No. 1 transmission clutch hub.
    4. Install the 3 synchronizer shifting key springs to the No. 1 transmission clutch hub.
    5. Place the balls in the holes of the No. 1 synchromesh shifting keys and install the No. 1 transmission hub sleeve while pushing in the balls.
      NOTE:

      Take care to prevent the balls from scattering.

    6. Coat the 1st driven gear synchronizer ring set with gear oil.
    7. Using SST and a press, install the No. 1 transmission hub to the No. 1 output shaft.
      GTY1022578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09726-40010 
      NOTE:

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

      HINT: 

      Make sure that the protruding part on the 1st driven gear synchronizer ring set is fitted into the groove of the No. 1 transmission clutch hub.

  4. INSTALL 2ND DRIVEN GEAR SYNCHRONIZER RING SET 
    1. Coat the 2nd driven gear synchronizer ring set with gear oil.
    2. Install the inner ring to the 2nd driven gear.
      GTY1022563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inner Ring
    3. Install the middle ring to the 2nd driven gear.
      GTY1022040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Middle Ring
    4. Install the outer ring to the 2nd driven gear.
      GTY1021496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Outer Ring
  5. INSTALL SYNCHROMESH SHIFTING KEY BALL 
    1. Using a Magnet Hand, install the synchromesh shifting key ball to the No. 1 output shaft.
      GTY1022291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NEEDLE ROLLER BEARING 
    1. Coat the needle roller bearing with gear oil and install it to the No. 1 output shaft.
      GTY1021718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL 2ND DRIVEN GEAR 
    1. Coat the 2nd driven gear with gear oil and install it to the No. 1 output shaft.
      GTY1021717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL 2ND DRIVEN GEAR BEARING INNER RACE 
    1. Align the groove of the 2nd driven gear bearing inner race with the synchromesh shifting key ball and install the 2nd driven gear bearing inner race.
      GTY1021735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING 
    1. Select a new output shaft bearing shaft snap ring, using the table below, that makes the thrust clearance of the 2nd driven gear bearing inner race less than 0.1 mm (0.00394 in.).
      GTY1022618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark
      OUTPUT SHAFT BEARING 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 snap ring expander, install the output shaft bearing shaft snap ring to the No. 1 output shaft.
      GTY1021734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Do not damage the journal surface of the No. 1 output shaft.

  10. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE 

    See step  12

  11. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE 

    See step  13

  12. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE 

    See step  14

  13. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE 

    See step  15

  14. INSTALL 4TH DRIVEN GEAR 
    1. Install the spacer to the No. 1 output shaft.
      GTY1021733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the needle roller bearing with gear oil and install it to the No. 1 output shaft.
      GTY1021732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the inner ring to the 4th driven gear.
      GTY1021951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inner Ring
    4. Install the middle ring to the 4th driven gear.
      GTY1021823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Middle Ring
    5. Install the outer ring to the 4th driven gear.
      GTY1022367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Outer Ring
    6. Coat the 4th driven gear with gear oil and install it to the No. 1 output shaft.
      GTY1022481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL NO. 2 TRANSMISSION CLUTCH HUB 
    1. Apply gear oil to the No. 2 transmission hub sleeve and No. 2 transmission clutch hub.
      GTY1023312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 2 transmission hub sleeve to the No. 2 transmission clutch hub.
    3. Install the 3 No. 1 synchromesh shifting keys to the No. 2 transmission clutch hub.
    4. Install the 3 synchronizer shifting key springs to the No. 2 transmission clutch hub.
    5. Place the balls in the holes of the No. 1 synchromesh shifting keys and install the No. 2 transmission hub sleeve while pushing in the balls.
      NOTE:

      Take care to prevent the balls from scattering.

    6. Coat the 4th driven gear synchronizer ring set with gear oil.
    7. Using SST and a press, install the No. 2 transmission clutch hub to the 4th driven gear.
      GTY1021885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09309-14010 
      NOTE:

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

      HINT: 

      Make sure that the protruding part on the 4th driven gear synchronizer ring set is fitted into the groove of the No. 2 transmission clutch hub.

  16. INSTALL SHAFT SNAP RING 
    1. Select a new shaft snap ring, using the table below, that makes the thrust clearance of the No. 2 transmission clutch hub less than 0.1 mm (0.00394 in.).
      GTY1022597Courtesy 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. 1 output shaft.
      GTY1021645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE 

    See step  18

  18. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE 

    See step  19

  19. INSTALL 3RD DRIVEN GEAR 
    1. Coat the 3rd driven gear synchronizer ring set with gear oil.
    2. Install the inner ring to the 3rd driven gear.
      GTY1021601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inner Ring
    3. Install the middle ring to the 3rd driven gear.
      GTY1022503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Middle Ring
    4. Install the outer ring to the 3rd driven gear.
      GTY1021343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Outer Ring
    5. Coat the needle roller bearing with gear oil and install it to the No. 1 output shaft.
      GTY1022463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Coat the 3rd driven gear with gear oil and install it to the No. 1 output shaft.
      GTY1251297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL OUTPUT SHAFT REAR BEARING 
    1. Using SST and a press, install the output shaft rear bearing (inner race) to the No. 1 output shaft.
      GTY1023930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-14010 
      NOTE:

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

      HINT: 

      When pressing in the bearing, apply force only to the inner race. Do not apply force to the seal.

  21. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING 
    1. Select a new output shaft bearing shaft snap ring, using the table below, that makes the thrust clearance of the output shaft rear bearing less than 0.1 mm (0.00394 in.).
      GTY1023444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark
      OUTPUT SHAFT BEARING SHAFT 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 output shaft bearing shaft snap ring to the No. 1 output shaft.
      GTY1024174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE 

    See step  16

  23. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE 

    See step  17

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