Output Shaft: Reassembly: Reassembly

INSTALL REVERSE GEAR

Fig 1: Installing No. 1 Synchromesh Shifting Keys
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the reverse gear with gear oil.
2. Install the 3 No. 1 synchromesh shifting key springs and No. 1 transaxle clutch hub to the reverse gear.
  NOTE:
  Assemble the reverse gear and the No. 1 transaxle clutch hub in the correct direction.
3. Using a screwdriver, install the 3 No. 1 synchromesh shifting keys to the reverse gear.
INSTALL OUTPUT SHAFT FRONT BEARING

Fig 2: Pressing In Front Bearing To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press in the front bearing (inner race) to the output shaft.
  - SST: 09950-60010
    - 09951-00430
  - SST: 09950-70010
    - 09951-07150
INSTALL NO. 1 SYNCHRONIZER RING SET

Fig 3: Identifying No. 1 Synchronizer Ring Set
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the No. 1 synchronizer ring set with gear oil, and install it to the 1st gear.
  NOTE:
  Align the claw of the No. 1 synchronizer ring set (middle) with the hole of the 1st gear and install it.
INSTALL 1ST GEAR NEEDLE ROLLER BEARING

Fig 4: Identifying 1st Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the needle roller bearing with gear oil, and install it to the output shaft.
INSTALL 1ST GEAR

Fig 5: Identifying 1st Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the 1st gear with gear oil, and install it to the output shaft.
INSTALL NO. 1 TRANSAXLE CLUTCH HUB

Fig 6: Pressing In No 1 Transmission Clutch Hub To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press in the No. 1 transaxle clutch hub to the output shaft.
  - SST: 09316-60011
    - 09316-00031
  - SST: 09950-60010
    - 09951-00320
  - SST: 09950-70010
    - 09951-07100
  NOTE:
  - Align the claw of the No. 1 synchronizer ring set (outer) with the hole of the No. 1 transaxle clutch hub and install it.
  - Make sure that the 1st gear rotates.
INSTALL 2ND GEAR BUSH BALL

Fig 7: Location of 2nd Gear Bush Ball
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the bush ball with MP grease, and install it to the output shaft.
INSTALL 2ND GEAR BUSH

Fig 8: Identifying 2nd Gear Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the bush with gear oil, and install it to the output shaft.
INSTALL 2ND GEAR BEARING SPACER

Fig 9: Identifying 2nd Gear Bearing Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the bearing spacer with gear oil, and install it to the output shaft.
INSTALL 2ND GEAR NEEDLE ROLLER BEARING

Fig 10: Identifying 2nd Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the needle roller bearing with gear oil, and install it to the output shaft.
INSTALL NO. 2 SYNCHRONIZER RING SET

Fig 11: Installing No. 2 Synchronizer Ring Set
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the No. 2 synchronizer ring set with gear oil, and install it to the No. 1 transaxle clutch hub.
  NOTE:
  Align the key groove on the No. 2 synchronizer ring set with the No. 1 synchromesh shifting key.
INSTALL 2ND GEAR

Fig 12: Identifying 2nd Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Coat the 2nd gear with gear oil, and install it to the output shaft.
INSTALL 3RD DRIVEN GEAR

Fig 13: Pressing In 3rd Driven Gear To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press in the 3rd driven gear to the output shaft.
  - SST: 09608-00071
  - SST: 09950-60010
    - 09951-00320
  - SST: 09950-70010
    - 09951-07100
INSTALL OUTPUT GEAR SPACER

Fig 14: Installing Output Gear Spacer To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the output gear spacer to the output shaft.
INSTALL 4TH DRIVEN GEAR

Fig 15: Pressing In 4th Driven Gear To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press in the 4th driven gear to the output shaft.
  - SST: 09608-00071
  - SST: 09950-60010
    - 09951-00320
  - SST: 09950-70010
    - 09951-07100
INSTALL OUTPUT SHAFT REAR BEARING

Fig 16: Pressing In Front Bearing (Inner Race) To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press in the rear bearing (inner race) to the output shaft.
  - SST: 09506-30012
  - SST: 09950-60010
    - 09951-00320
  - SST: 09950-70010
    - 09951-07100

INSPECT 2ND GEAR RADIAL CLEARANCE

Fig 17: Measuring Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a dial indicator, measure the radial clearance.

Standard clearance

Bearing	Specified Condition
JTEKT made	0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made	0.009 to 0.051 mm (0.0004 to 0.0020 in.)

If the clearance is out of the specification, replace the 2nd gear, 2nd gear bush and 2nd gear needle roller bearing.

INSPECT 1ST GEAR RADIAL CLEARANCE

Fig 18: Measuring Radial Clearance

Using a dial indicator, measure the radial clearance.

Standard clearance

Bearing	Specified Condition
JTEKT made	0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made	0.009 to 0.051 mm (0.0004 to 0.0020 in.)

If the clearance is out of the specification, replace the 1st gear and 1st gear needle roller bearing.

INSPECT 2ND GEAR THRUST CLEARANCE

Fig 19: Measuring Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a dial indicator, measure the thrust clearance.
  Standard clearance
  
  0.10 to 0.35 mm (0.0039 to 0.0138 in.)
  
  If the clearance is out of the specification, replace the No. 1 transaxle clutch hub, 2nd gear or 3rd driven gear.
INSPECT 1ST GEAR THRUST CLEARANCE

Fig 20: Measuring Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a feeler gauge, measure the thrust clearance.
  Standard clearance
  
  0.25 to 0.40 mm (0.0098 to 0.0157 in.)
  
  If the clearance is out of the specification, replace the 1st gear or No. 1 transaxle clutch hub.