Toyota Yaris: Output Shaft / Disassembly

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Drivetrain / Ea67f (manual Transmission / Transaxle) / 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.

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

11. REMOVE SPACER

(a) Remove the spacer from the No. 1 output shaft.

12. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

(a) Remove the needle roller bearing from the No. 1 output shaft.

13. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET

(a) Remove the 3rd driven gear synchronizer ring set from the No. 1 output shaft.

14. REMOVE SHAFT SNAP RING

(a) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 1 output shaft.

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

16. REMOVE 4TH DRIVEN GEAR SYNCHRONIZER RING SET

(a) Remove the 4th driven gear synchronizer ring set from the 4th driven gear.

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.

18. REMOVE 4TH GEAR BEARING SPACER

(a) Remove the needle roller bearing from the No. 1 output shaft.

19. REMOVE SPACER

(a) Remove the spacer from the No. 1 output shaft.

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.

21. REMOVE 2ND GEAR BEARING INNER RACE

(a) Remove the 2nd driven gear bearing inner race from the No. 1 output shaft.

22. REMOVE 2ND DRIVEN GEAR

(a) Remove the 2nd driven gear from the No. 1 output shaft.

23. REMOVE NEEDLE ROLLER BEARING

(a) Remove the needle roller bearing from the No. 1 output shaft.

24. REMOVE SYNCHROMESH SHIFTING KEY BALL

(a) Using a magnet hand, remove the synchromesh shifting key ball from the No. 1 output shaft.

*a

Magnet Hand

25. REMOVE NO. 1 SYNCHRONIZER RING SET

(a) Remove the 2nd driven gear synchronizer ring set from the No. 1 output shaft.

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

27. REMOVE 1ST DRIVEN GEAR SYNCHRONIZER RING SET

(a) Remove the 1st driven synchronizer ring set from the 1st driven gear.

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.

29. REMOVE NEEDLE ROLLER BEARING

(a) Remove the needle roller bearing from the No. 1 output shaft.

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

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.

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

39. REMOVE NEEDLE ROLLER BEARING

(a) Remove the needle roller bearing from the No. 2 output shaft.

40. REMOVE SPACER

(a) Remove the spacer from the No. 2 output shaft.

41. REMOVE 6TH DRIVEN GEAR SYNCHRONIZER RING

(a) Remove the 6th driven gear synchronizer ring from the No. 2 output shaft.

42. REMOVE SHAFT SNAP RING

(a) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 2 output shaft.

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

44. REMOVE 5TH DRIVEN GEAR SYNCHRONIZER RING

(a) Remove the 5th driven gear synchronizer ring from the 5th driven gear.

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.

46. REMOVE SHAFT SNAP RING

(a) Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 2 output shaft.

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

48. REMOVE REVERSE DRIVEN GEAR SYNCHRONIZER RING

(a) Remove the reverse driven gear synchronizer ring from the reverse driven gear.

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.

*1

Hub Sleeve

*2

Shifting Key

*3

Key Spring

*4

No. 4 Transmission Clutch Hub

50. REMOVE NEEDLE ROLLER BEARING

(a) Remove the needle roller bearing from the No. 2 output shaft.

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

    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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