Toyota Yaris: Output Shaft / Disassembly
DISASSEMBLY
PROCEDURE
1. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE
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2. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE
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3. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE
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4. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE
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5. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE
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6. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE
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7. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE
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8. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE
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9. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING
| (a) Using a snap ring expander, remove the output shaft bearing shaft snap ring from the No. 1 output shaft. |
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10. REMOVE OUTPUT SHAFT REAR BEARING
| (a) Using SST and a press, remove the output shaft rear bearing from the No. 1 output shaft. SST: 09201-31010 SST: 09950-00020 |
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11. REMOVE SPACER
| (a) Remove the spacer from the No. 1 output shaft. |
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12. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
| (a) Remove the needle roller bearing from the No. 1 output shaft. |
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13. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET
| (a) Remove the 3rd driven gear synchronizer ring set from the No. 1 output shaft. |
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14. REMOVE SHAFT SNAP RING
| (a) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 1 output shaft. |
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15. REMOVE 4TH DRIVEN GEAR
| (a) Using SST and a press, remove the No. 2 transmission hub sleeve, 4th driven gear synchronizer ring set, and 4th driven gear from the No. 1 output shaft. SST: 09950-00020 |
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16. REMOVE 4TH DRIVEN GEAR SYNCHRONIZER RING SET
| (a) Remove the 4th driven gear synchronizer ring set from the 4th driven gear. |
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17. REMOVE NO. 2 TRANSMISSION CLUTCH HUB
| (a) Remove the No. 2 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 balls and 3 synchronizer shifting key springs from the No. 2 transmission hub sleeve. NOTICE: Pay attention to prevent the balls and synchronizer shifting key springs from scattering. |
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18. REMOVE 4TH GEAR BEARING SPACER
| (a) Remove the needle roller bearing from the No. 1 output shaft. |
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19. REMOVE SPACER
| (a) Remove the spacer from the No. 1 output shaft. |
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20. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING
| (a) Using a snap ring expander, remove the output shaft bearing shaft snap ring from the No. 1 output shaft. |
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21. REMOVE 2ND GEAR BEARING INNER RACE
| (a) Remove the 2nd driven gear bearing inner race from the No. 1 output shaft. |
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22. REMOVE 2ND DRIVEN GEAR
| (a) Remove the 2nd driven gear from the No. 1 output shaft. |
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23. REMOVE NEEDLE ROLLER BEARING
| (a) Remove the needle roller bearing from the No. 1 output shaft. |
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24. REMOVE SYNCHROMESH SHIFTING KEY BALL
| (a) Using a magnet hand, remove the synchromesh shifting key ball from the No. 1 output shaft. |
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25. REMOVE NO. 1 SYNCHRONIZER RING SET
| (a) Remove the 2nd driven gear synchronizer ring set from the No. 1 output shaft. |
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26. REMOVE 1ST DRIVEN GEAR
| (a) Using SST and a press, remove the No. 1 transmission hub sleeve, 1st driven gear synchronizer ring set and 1st driven gear from the No. 1 output shaft. SST: 09950-00020 |
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27. REMOVE 1ST DRIVEN GEAR SYNCHRONIZER RING SET
| (a) Remove the 1st driven synchronizer ring set from the 1st driven gear. |
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28. REMOVE NO. 1 TRANSMISSION CLUTCH HUB
| (a) Remove the No. 1 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 balls and 3 synchronizer shifting key springs from the No. 1 transmission hub sleeve. NOTICE: Pay attention to prevent the balls and synchronizer shifting key springs from scattering. |
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29. REMOVE NEEDLE ROLLER BEARING
| (a) Remove the needle roller bearing from the No. 1 output shaft. |
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30. REMOVE OUTPUT SHAFT FRONT BEARING INNER RACE
| (a) Using SST and a press, remove the output shaft front bearing inner race from the No. 1 output shaft. SST: 09201-31010 SST: 09950-00020 |
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31. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE
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32. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE
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33. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE
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34. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE
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35. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE
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36. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE
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37. REMOVE NO. 2 OUTPUT SHAFT BEARING SNAP RING
| (a) Using a snap ring expander, remove the No. 2 output shaft bearing snap ring from the No. 2 output shaft. |
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38. REMOVE NO. 2 OUTPUT SHAFT REAR BEARING
| (a) Using SST and a press, remove the No. 2 output shaft rear bearing and 6th driven gear from the No. 2 output shaft. SST: 09201-31010 SST: 09950-00020 |
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39. REMOVE NEEDLE ROLLER BEARING
| (a) Remove the needle roller bearing from the No. 2 output shaft. |
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40. REMOVE SPACER
| (a) Remove the spacer from the No. 2 output shaft. |
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41. REMOVE 6TH DRIVEN GEAR SYNCHRONIZER RING
| (a) Remove the 6th driven gear synchronizer ring from the No. 2 output shaft. |
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42. REMOVE SHAFT SNAP RING
| (a) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 2 output shaft. |
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43. REMOVE 5TH DRIVEN GEAR
| (a) Using SST and a press, remove the No. 3 transmission hub sleeve, 5th driving gear synchronizer ring, 5th driven gear, 2 spacers and needle roller bearing from the No. 2 output shaft. SST: 09950-00020 |
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44. REMOVE 5TH DRIVEN GEAR SYNCHRONIZER RING
| (a) Remove the 5th driven gear synchronizer ring from the 5th driven gear. |
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45. REMOVE NO. 3 TRANSMISSION CLUTCH HUB
| (a) Remove the No. 3 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 ball and 3 synchronizer shifting key springs from the No. 3 transmission hub sleeve. NOTICE: Pay attention to prevent the balls and synchronizer shifting key springs from scattering. |
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46. REMOVE SHAFT SNAP RING
| (a) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 2 output shaft. |
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47. REMOVE REVERSE DRIVEN GEAR
| (a) Using SST and a press, remove the No. 4 transmission hub sleeve, reverse driven gear synchronizer ring and reverse driven gear from the No. 2 output shaft. SST: 09950-00020 |
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48. REMOVE REVERSE DRIVEN GEAR SYNCHRONIZER RING
| (a) Remove the reverse driven gear synchronizer ring from the reverse driven gear. |
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49. REMOVE NO. 4 TRANSMISSION CLUTCH HUB
| (a) Remove the No. 4 transmission clutch hub, key spring and shifting key from the No. 4 transmission hub sleeve. |
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50. REMOVE NEEDLE ROLLER BEARING
| (a) Remove the needle roller bearing from the No. 2 output shaft. |
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51. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING
| (a) Using SST and a press, remove the No. 2 output shaft front bearing from the No. 2 output shaft. SST: 09201-31010 SST: 09950-00020 |
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Components
COMPONENTS ILLUSTRATION
*1 OUTPUT SHAFT BEARING SHAFT SNAP RING *2 NEEDLE ROLLER BEARING *3 SYNCHRONIZER SHIFTING KEY SPRING *4 SHAFT SNAP RING *5 SPACER *6 BALL *7 OUTPUT SHAFT FRONT BEARING INNER RACE *8 SYNCHROMESH SHIFTING KEY BALL *9 NO...
Inspection
INSPECTION PROCEDURE 1. INSPECT NO. 1 OUTPUT SHAFT (a) Check the No. 1 output shaft for wear and damage.
(b) Using a dial indicator, check the No...
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Keys
To use the auxiliary key, press the knob and pull out the auxiliary key from the smart key.
