Counter Shaft: Reassembly

INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
1. Using SST and a press, press in the front drive pinion rear tapered roller bearing of the thick inner race side.
  
  Fig 1: Installing Front Drive Pinion Rear Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the thick front drive pinion rear tapered roller bearing outer race to the flange side of the differential drive pinion.
  
  Fig 2: Pressing Thick Front Drive Pinion Rear Tapered Roller Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in the thick front drive pinion front tapered roller bearing race to the other side.
  SST 09350-32014 (09351-32180)
  
  Fig 3: Pressing Thick Front Drive Pinion Front Tapered Roller Bearing Race To Other Side
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE PLANETARY RING GEAR
1. Install the underdrive planetary ring gear to the counter shaft assembly.
  
  Fig 4: Installing Underdrive Planetary Ring Gear To Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the snap ring to the counter shaft assembly.
  SST 09350-32014 (09351-32090, 09351-32180, 09351-32150)
  
  Fig 5: Installing Snap Ring To Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL DRIVE PINION
1. Install a new front differential drive pinion bearing spacer to the counter shaft assembly.
  
  Fig 6: Installing Front Differential Drive Pinion Bearing Spacer To Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the differential drive pinion to the counter shaft assembly.
  
  Fig 7: Installing Differential Drive Pinion To Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
1. Using SST and a press, press in the another front drive pinion front tapered roller bearing.
  SST 09350-32014 (09351-32180)
  
  NOTE: Be sure there is some clearance between the output flange and bearing.
  
  Fig 8: Installing Front Drive Pinion Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
1. Using SST and a press, press in the underdrive cylinder roller bearing.
  SST 09350-32014 (09351-32180)
  
  NOTE: Be sure there is some clearance.
  
  Fig 9: Installing Underdrive Cylindrical Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADJUST COUNTER SHAFT ASSEMBLY
1. Using SST and a press, press in the counter driven gear to the counter shaft assembly.
  SST 09350-32014 (09351-32100)
  
  Fig 10: Pressing Counter Driven Gear To Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install SST to the counter driven gear.
  SST 09350-32014 (09351-32032)
  
  Fig 11: Installing SST To Counter Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Secure the counter shaft assembly by holding the SST by a vise.
  SST 09350-32014 (09351-32032)
  
  Fig 12: Installing Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install a new lock nut, and using SST, tighten the underdrive input shaft nut until the counter shaft starting torque comes to the specified value.
  SST 09350-32014 (09351-32170)
  
  Torque: (Reference)
  
  180 N*m (1,835 kgf*cm, 132 ft.*lbf)
  
  Fig 13: Tightening Underdrive Input Shaft Nut Until Counter Shaft Starting
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Use a torque wrench with a fulcrum length of 42 cm (16.54 in.).
6. Using soft jaws, hold the drive pinion by a vise.
7. Using SST and spring tension gauge, measure the starting torque of the counter shaft assembly.
  SST 09350-32014 (09351-32170)
  
  Starting torque:
  
  with tension gauge
  
  1.2 to 2.0 kg (2.6 to 4.4 lb)
  
  with torque wrench (hexagon nut side)
  
  Torque: New bearing
  
  0.6 to 1.0 N*m (6 to 10 kgf*cm, 5.2 to 8.7 in.*lbf)
  
  Reused bearing
  
  0.3 to 0.5 N*m (3 to 5 kgf*cm, 2.6 to 4.3 in.*lbf)
  
  Fig 14: Measuring Starting Torque Of Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the starting torque exceeds the limit, replace the spacer and retorque.
  
  HINT:
  
  Before measuring the starting torque, snug down the bearing by turning the counter shaft.
8. Using a punch and hammer, stake the underdrive input shaft nut.
9. Remove SST from the counter driven gear.
  SST 09350-32014 (09351-32032)
  
  Fig 15: Removing SST From Counter Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using SST, remove the counter driven gear from the counter shaft assembly.
  SST 09350-32014 (09351-32061)
  
  Fig 16: Removing Counter Driven Gear From Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE INPUT SHAFT THRUST BEARING RACE

Coast the underdrive input shaft thrust bearing race with petroleum jelly and install them to the counter shaft assembly.

Race: mm (in.)

RACE SPECIFICATIONS

	Outer diameter	Inner diameter
Race	41.8 mm (1.646 in.)	30.0 mm (1.181 in.)

Fig 17: Installing Underdrive Input Shaft Thrust Bearing Race

G05234430

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE INPUT SHAFT NEEDLE ROLLER BEARING

Coat the underdrive input shaft needle roller bearing with petroleum jelly and install them to the counter shaft assembly.

Bearing: mm (in.)

BEARING SPECIFICATIONS

	Outer diameter	Inner diameter
Bearing	43.85 mm (1.7264 in.)	31.0 mm (1.220 in.)

INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
1. Install the underdrive planetary gear assembly to the counter shaft assembly.
  
  Fig 18: Installing Underdrive Planetary Gear Assembly To Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the underdrive planetary gear hole snap ring to the counter shaft assembly.
  
  Fig 19: Installing Underdrive Planetary Gear Hole Snap Ring To Counter Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE PLANETARY SUN GEAR HOLE SNAP RING
1. Using snap ring pliers, install the underdrive planetary sun gear hole snap ring to the underdrive planetary sun gear sub-assembly.
  
  Fig 20: Installing Underdrive Planetary Sun Gear Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE PLANETARY SUN GEAR SUB-ASSEMBLY
1. Install the underdrive planetary sun gear sub-assembly to the counter shaft assembly.
  
  Fig 21: Installing Underdrive Planetary Sun Gear Subassembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002