Info

2nd Gear Synchronizer Ring Clutch Hub & Sleeve

Snap Ring 1 st & Reverse Gear

Hub Sleeve Toyota

2. Assemble the parts in the numerical order shown in the figure.

Fig. 3-138

6 Reverse Idler Gear

7. Counter Gear

8 Input Shaft & Synchronizer Ring

9. Countershaft & Key

10. Output Shaft

11. Bearing

12 Shift Fork & Shaft

13. Front Bearing Retainer

14 Case Cover

Fig. 3-139

0 Install the snap ring with SST. SST [09905-00012]

Fig. 3-140

Fig. 3-140

Measure the 2nd gear thrust clearance. Thrust clearance:

(0.016 in.) Snap ring thickness

Part No.

Thickness mm (in.)

90520-33132

2.35-2.40 (0.0925-0.0945)

90520-33172

2.25-2.30 (0.0886-0.0906)

Fig. 3-141

n.

Reverse Idler Gear / Washer

/^Thrust Washer

j

j/ L

Bearing

■(III

P

^^Shaft

lZIJ

Woodruff key

Fig. 3-142

Install as illustrated at left. - Note -

Coat MP grease on the bearing, washer, and spacer before installing.

Fig. 3-142

Thrust Washer Thrust WasherA

Thrust Washer Thrust WasherA

0 Assemble the counter gear assembly as illustrated at left, and install in the case with SST.

Coat MP grease on the bearing, washer, and spacer before installing.

Fig. 3-143

Fig. 3-143

Fig. 3-144
Drive in the countershaft and key.

Fig. 3-145

Fig. 3-145

Measure the counter gear thrust clearance. Thrust clearance:

Thrust washer thickness

Part No.

Thickness mm (in.)

33441-61010

33442-61010

33443-61010

1.45-1.50 (0.0571-0.0591) 1.50-1.55 (0.0591-0.0610) 1.55-1.60 (0.0610-0.0630)

Fig. 3-146

Fig. 3-146

0 Drive in the bearing with SST SST [09316-60010]

Position the hub sleeve at 3rd gear, and insert the output shaft assembly into the case.

Fig. 3-147

Fig. 3-147

Install the retainer with its oil hole positioned downward.

While holding down the locking ball, drive in the shaft, and then lock the shaft with a straight pin.

While holding down the locking ball, drive in the shaft, and then lock the shaft with a straight pin.

Install the retainer with its oil hole positioned downward.

Fig. 3-149

INSTALLATION

Install the parts in the numerical order shown in the figure.

Fig. 3-149

3 Fig. 3-153 4

1. Transfer & Gear

2. Bearing

3. Spacer, Washer & Nut 4 No.2 Case Cover

5. Power Take Off or Cover

6. Shift Lever Guide 7 Lever & Rod

Fig. 3-150

Fig. 3-150

Fig. 3-151

Fig. 3-151

0 Mount SST to the output shaft. While supporting the gears with one hand, install the transfer assembly together with the gears to the SST.

Align the splines of the output shaft and gears, and install the transfer to the transmission. SST [09323-60010]

Make sure that the gears are positioned in correct direction.

Remove the SST from the output shaft.

r^TH Tighten the five bolts at the specified torque. Tightening torque:

Fig. 3-152

Fig. 3-152

Bearing

0 Drive in the bearing with SST. SST [09316-60010]

Fig. 3-153

Fig. 3-153

Keep the transfer output shaft from turning and tighten the nut with SST. SST [09330-00020]

Tightening torque:

11.0-14.0 kg-m (80 - 101 ft-lb) Secure the nut with lock washer.

Perform the work with transmission in front drive.

TRANSFER

Page

TRANSFER (J30) 4-26

TRANSMISSION REMOVAL SECTION Fig. 3-2 to 3-5

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