Output Shaft: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL NO. 1 CLUTCH HUB INTO NO. 1 HUB SLEEVE 
   1. Install the 3 springs and shifting keys to the clutch hub.
   2. Install the hub sleeve to the clutch hub.
      NOTE: Assemble the clutch hub and hub sleeve in the direction shown in the illustration.
      Fig 1: Installing No. 1 Clutch Hub Into No. 1 Hub Sleeve

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL 1ST GEAR BEARING INNER RACE 

   Using SST and a press, install the 1st gear bearing inner race.

   SST 09506-35010

   HINT:

   Align the hole of the output shaft and inner race.

   Fig 2: Installing 1st Gear Bearing Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RINGS AND NO. 1 HUB SLEEVE TO OUTPUT SHAFT 
   1. Apply MP grease to the needle roller bearing and install it.
   2. Place the synchronizer rings on the 1st gear.
   3. Install the 1st gear.
      Fig 3: Placing 1st Gear, Synchronizer Rings & No. 1 Hub Sleeve To Output Shaft

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Using SST and a press, install the 1st gear and No. 1 hub sleeve.

      SST 09316-60011 (09316-00041)

      Fig 4: Installing 1st Gear & No. 1 Hub Sleeve

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. MEASURE 1ST GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
5. INSTALL BALL AND INNER RACE TO OUTPUT SHAFT 

   HINT:

   Align the groove of the inner race and ball.

   Fig 5: Installing Ball And Inner Race To Output Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RINGS, 2ND GEAR AND 3RD DRIVEN GEAR 
   1. Install the spacer.
   2. Apply MP grease to the needle roller bearing.
   3. Place the synchronizer rings on the 2nd gear.
   4. Install the 2nd gear.
   5. Using a press, install the 3rd driven gear.
      Fig 6: Using A Press, Install 3rd Driven Gear

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Align the clutch hub grooves with the projections on the synchronizer ring.
      Fig 7: Aligning Clutch Hub Grooves With Projections On Synchronizer Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. MEASURE 2ND GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
8. INSTALL SPACER AND 4TH DRIVEN GEAR 
   1. Install the spacer.
   2. Using a press, install the 4th driven gear.
      Fig 8: Installing Spacer & 4th Driven Gear

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. INSTALL OUTPUT SHAFT REAR BEARING 

   Using SST and a press, install a new bearing.

   SST 09506-30012

   Fig 9: Installing NEW Output Shaft Rear Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL OUTPUT SHAFT FRONT BEARING 

    Using SST and a press, install a new output shaft front bearing.

    SST 09316-60011 (09316-00071)

    Fig 10: Installing New Output Shaft Front Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002