Output Shaft Disassembly

Transmission. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
Eb61 Manual Transaxle. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. INSPECT 1ST GEAR THRUST CLEARANCE

  2. INSPECT 2ND GEAR THRUST CLEARANCE

  3. INSPECT 1ST GEAR RADIAL CLEARANCE

  4. INSPECT 2ND GEAR RADIAL CLEARANCE

  5. REMOVE 6TH DRIVEN GEAR

  6. REMOVE OUTPUT GEAR SPACER

  7. REMOVE 4TH DRIVEN GEAR

  8. REMOVE OUTPUT GEAR SPACER

  9. REMOVE 2ND GEAR

  10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

  11. REMOVE INNER 2ND GEAR BEARING RACE

  12. REMOVE NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)

  13. REMOVE REVERSE GEAR

  14. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY

  15. REMOVE NO. 1 TRANSMISSION CLUTCH HUB

  16. REMOVE NO. 1 SYNCHRONIZER RING SET (for 1st Gear)

  17. REMOVE 1ST GEAR

  18. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

  19. REMOVE 1ST GEAR BUSH

  20. REMOVE FRONT OUTPUT SHAFT BEARING

Output Shaft -- Disassembly



1. INSPECT 1ST GEAR THRUST CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 1st gear thrust clearance.

    Standard clearance:
    0.23 to 0.37 mm (0.00905 to 0.0146 in.)
    Maximum clearance:
    0.37 mm (0.0146 in.)
    If the clearance is more than the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear. Replace the part or parts determined to be the most likely cause of the problem.


2. INSPECT 2ND GEAR THRUST CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 2nd gear thrust clearance.

    Standard clearance:
    0.16 to 0.33 mm (0.00629 to 0.0130 in.)
    Maximum clearance:
    0.33 mm (0.0130 in.)
    If the clearance is more than the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear. Replace the part or parts determined to be the most likely cause of the problem.


3. INSPECT 1ST GEAR RADIAL CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 1st gear radial clearance.

    Standard clearance:
    0.009 to 0.047 mm (0.000354 to 0.00185 in.)
    Maximum clearance:
    0.047 mm (0.00185 in.)
    If the clearance is more than the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.


4. INSPECT 2ND GEAR RADIAL CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 2nd gear radial clearance.

    Standard clearance:
    0.009 to 0.047 mm (0.000354 to 0.00185 in.)
    Maximum clearance:
    0.047 mm (0.00185 in.)
    If the clearance is more than the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.


5. REMOVE 6TH DRIVEN GEAR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Output Shaft Disassembly

  1. Using SST, remove the rear output shaft bearing and 6th driven gear from the output shaft.

    SST
    09950-40011(09951-04010,09952-04010,09953-04020,09954-04010,09955-04021,09957-04010,09958-04011)
    09950-60010(09951-00180,09951-00270,09952-06010)


6. REMOVE OUTPUT GEAR SPACER


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the output gear spacer from the output shaft.



7. REMOVE 4TH DRIVEN GEAR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Output Shaft Disassembly

  1. Using SST and a press, press out the 5th driven gear and 4th driven gear from the output shaft.

    SST
    09527-10011
    09950-40011(09957-04010)
    09950-60010(09951-00180,09951-00270,09952-06010)
    NOTICE:
    Support the output shaft by hand to prevent it from falling.


8. REMOVE OUTPUT GEAR SPACER


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the output gear spacer from the output shaft.



9. REMOVE 2ND GEAR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Output Shaft Disassembly

  1. Using SST, remove the 3rd driven gear and 2nd gear from the output shaft.

    SST
    09950-40011(09951-04010,09952-04010,09953-04020,09954-04030,09955-04021,09957-04010,09958-04011)
    09950-60010(09951-00180,09951-00270,09952-06010)


10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2nd gear needle roller bearing from the output shaft.



11. REMOVE INNER 2ND GEAR BEARING RACE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the inner 2nd gear bearing race from the output shaft.



12. REMOVE NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the No. 1 synchronizer ring set from the reverse gear.



13. REMOVE REVERSE GEAR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Output Shaft Disassembly

  1. Remove the reverse gear from the No. 1 transmission clutch hub.



14. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 3 No. 1 synchromesh shifting keys from the No. 1 transmission clutch hub.



15. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the No. 1 transmission clutch hub from the output shaft.



16. REMOVE NO. 1 SYNCHRONIZER RING SET (for 1st Gear)


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the No. 1 synchronizer ring set from the 1st gear.



17. REMOVE 1ST GEAR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 1st gear from the output shaft.



18. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 1st gear needle roller bearing from the output shaft.



19. REMOVE 1ST GEAR BUSH


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 1st gear bush from the output shaft.



20. REMOVE FRONT OUTPUT SHAFT BEARING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Output Shaft Disassembly

  1. Using SST and a press, remove the front output shaft bearing from the output shaft.

    SST
    09950-00020
    09950-00030
    09950-40011(09957-04010)
    09950-60010(09951-00180,09951-00340,09952-06010)