Выходной Вал Повторная Сборка. Corolla ZZE150

Coat the needle roller bearing with gear oil and install it to the No. 2 output shaft.

Coat the reverse driven gear with gear oil and install it to the No. 2 output shaft.

Install the key spring and 2 shifting keys to the clutch hub.

УКАЗАНИЕ:

1. Install the shifting keys with the grooves on the clutch hub side.
   
2. Install the key spring with the claw on the clutch hub side.
   
3. Refer to the illustration when installing the key spring and shifting keys.
   

Install the hub sleeve to the reverse driven gear as shown in the illustration.

Coat the No. 4 transmission clutch hub with gear oil and install it to the No. 2 output shaft.

Using SST and a press, install the reverse gear and No. 4 transmission clutch hub to the No. 2 output shaft.

SST

09308-14010

ПРИМЕЧАНИЕ:

During and after installation, make sure that the gear and synchronizer ring move smoothly.

УКАЗАНИЕ:

Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

Select a new snap ring, using the table below, that makes the thrust clearance of the No. 4 transmission clutch hub less than 0.1 mm (0.0039 in.).

Using a brass bar and hammer, tap the snap ring onto the No. 2 output shaft.

ПРИМЕЧАНИЕ:

If the transmission clutch hub is not fully pressed on the shaft, or if its thrust clearance is excessive, the driven gear thrust clearance may also be excessive.

Using a feeler gauge, measure the reverse driven gear thrust clearance.

Standard clearance:

0.11 to 0.34 mm (0.0043 to 0.0134 in.)

Maximum clearance:

0.34 mm (0.0134 in.)

ПРИМЕЧАНИЕ:

1. Support both ends of the output shaft at all times when the output shaft is mounted in a horizontal position. Failure to support both ends of the shaft will result in the shaft falling out of the vise.
   
2. Only secure the output shaft in a vice which has soft jaws. Failure to use caution when mounting or working on the output shaft can result in damage to bearings, bearing surfaces or damage to gear teeth.
   

Using a dial indicator, measure the reverse driven gear radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Maximum clearance:

0.068 mm (0.0027 in.)

УКАЗАНИЕ:

Make sure that the output shaft is mounted rigidly when measuring the radial clearance. If the output shaft moves, the measurement will be inaccurate.

Install the output shaft spacer to the No. 2 output shaft.

Coat the needle roller bearing with gear oil and install it to the No. 2 output shaft.

Install the output shaft spacer to the No. 2 output shaft.

Coat the 5th driven gear with gear oil and install it to the No. 2 output shaft.

Apply gear oil to the sleeve and hub.

Install the clutch hub sleeve to the clutch hub.

Install the 3 shifting keys to the clutch hub.

Install the 3 shifting key springs to the clutch hub.

Place the balls in the holes of the shifting keys and install the hub sleeve while pushing in the balls.

ПРИМЕЧАНИЕ:

Take care to prevent the balls from scattering.

Coat the 5th driven gear synchronizer ring with gear oil and install it to the 5th driven gear.

Using SST and a press, install the No. 3 transmission clutch hub to the No. 2 output shaft.

SST

09308-14010

ПРИМЕЧАНИЕ:

After installation, make sure that the gear and synchronizer ring move smoothly.

УКАЗАНИЕ:

Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

Select a new snap ring, using the table below, that makes the thrust clearance of the No. 3 transmission clutch hub less than 0.1 mm (0.0039 in.).

Using a brass bar and hammer, tap the snap ring onto the No. 2 output shaft.

ПРИМЕЧАНИЕ:

If the transmission clutch hub is not fully pressed on the shaft, or if its thrust clearance is excessive, the driven gear thrust clearance may also be excessive.

Using a feeler gauge, measure the 5th driven gear thrust clearance.

Standard clearance:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

Using a dial indicator, measure the 5th driven gear radial clearance.

Standard clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum clearance:

0.066 mm (0.0026 in.)

УКАЗАНИЕ:

Make sure that the output shaft is mounted rigidly when measuring the radial clearance. If the output shaft moves, the measurement will be inaccurate.

Install the output shaft spacer to the No. 2 output shaft.

Coat the needle roller bearing with gear oil and install it to the No. 2 output shaft.

Coat the synchronizer ring with gear oil and install it to the transmission clutch hub.

Coat the 6th driven gear with gear oil and install it to the No. 2 output shaft.

ПРИМЕЧАНИЕ:

After placing the gear on the shaft, make sure that the synchronizer is correctly aligned with the shifting keys on the hub.

Using SST and a press, install the No. 2 output shaft rear bearing to the No. 2 output shaft.

SST

09710-04071

ПРИМЕЧАНИЕ:

During and after installation, make sure that the gear and synchronizer ring move smoothly.

Select a new snap ring, using the table below, that makes the thrust clearance of the 6th gear less than 0.1 mm (0.0039 in.).

Using a snap ring expander, install the snap ring onto the No. 2 output shaft.

ПРИМЕЧАНИЕ:

If the bearing is not fully pressed on the shaft, or if its thrust clearance is excessive, the driven gear thrust clearance may also be excessive.

Using a feeler gauge, measure the 6th driven gear thrust clearance.

Standard clearance:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

ПРИМЕЧАНИЕ:

1. Use caution when securing the output shaft in a vise. Use only a soft jawed vise. Use a shop rag or a piece of cloth to help protect the teeth of the gear. Do not overtighten the vise.
   
2. Support both ends of the output shaft at all times when the output shaft is mounted in a horizontal position. Failure to support both ends of the shaft will result in the shaft falling out of the vise.
   

Using a dial indicator, measure the 6th driven gear radial clearance.

Standard clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum clearance:

0.066 mm (0.0026 in.)

УКАЗАНИЕ:

Make sure that the output shaft is mounted rigidly when measuring the radial clearance. If the output shaft moves, the measurement will be inaccurate.

Using SST and a press, install the No. 2 output shaft front bearing to the No. 2 output shaft.

SST

09309-37010
09506-30012

Using SST and a press, install the output shaft front bearing inner race to the No. 1 output shaft.

SST

09309-14040

Using a snap ring expander, install a new snap ring to the No. 1 output shaft.

Coat the needle roller bearing with gear oil and install it to the No. 1 output shaft.

Install the inner ring onto the 1st driven gear.

Install the middle ring onto the 1st driven gear.

Install the outer ring onto the 1st driven gear.

Coat the 1st driven gear with gear oil and install it to the No. 1 output shaft.

Apply gear oil to the sleeve and hub.

Install the clutch hub sleeve to the clutch hub.

Install the 3 shifting keys to the clutch hub.

Install the 3 shifting key springs to the clutch hub.

Place the balls in the holes of the shifting keys and install the hub sleeve while pushing in the balls.

ПРИМЕЧАНИЕ:

Take care to prevent the balls from scattering.

Coat the 1st driven gear synchronizer ring set with gear oil.

Using SST and a press, install the No. 1 transmission hub sleeve to the No. 1 output shaft.

SST

09726-40010

ПРИМЕЧАНИЕ:

During and after installation, make sure that the gear and synchronizer ring move smoothly.

УКАЗАНИЕ:

Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

Coat the 2nd driven gear synchronizer ring set with gear oil.

Install the outer ring onto the 2nd driven gear.

Install the middle ring onto the 2nd driven gear.

Install the inner ring onto the 2nd driven gear.

Install the key ball onto the No. 1 output shaft.

Coat the needle roller bearing with gear oil and install it to the No. 1 output shaft.

Coat the 2nd driven gear with gear oil and install it to the No. 1 output shaft.

Align the groove of the 2nd driven gear bearing inner race with the ball and install the inner race.

Select a new snap ring, using the table below, that makes the thrust clearance of the 2nd driven gear bearing inner race less than 0.1 mm (0.0039 in.).

Using a snap ring expander, install the snap ring to the No. 1 output shaft.

УКАЗАНИЕ:

Do not damage the journal surface of the No. 1 output shaft.

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

Standard clearance:

0.10 to 0.35 mm (0.0039 to 0.0138 in.)

Maximum clearance:

0.35 mm (0.0138 in.)

ПРИМЕЧАНИЕ:

1. Only secure the output shaft in a vice which has soft jaws. Failure to use caution when mounting or working on the output shaft can result in damage to bearings, bearing surfaces or damage to gear teeth.
   
2. Use caution when working with an output shaft secured in a vise. The output shaft is heavy, and may be knocked from the vise easily.
   

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

Standard clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Maximum clearance:

0.068 mm (0.0027 in.)

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

Standard clearance:

0.11 to 0.46 mm (0.0043 to 0.0181 in.)

Maximum clearance:

0.46 mm (0.0181 in.)

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

Standard clearance:

0.015 to 0.048 mm (0.0006 to 0.0019 in.)

Maximum clearance:

0.048 mm (0.0019 in.)

Install the output shaft spacer to the No. 1 output shaft.

Coat the 4th driven gear needle roller bearing with gear oil and install it to the No. 1 output shaft.

Install the inner ring onto the 4th driven gear.

Install the middle ring onto the 4th driven gear.

Install the outer ring onto the 4th driven gear.

Coat the 4th driven gear with gear oil and install it to the No. 1 output shaft.

Apply gear oil to the sleeve and hub.

Install the clutch hub sleeve to the clutch hub.

Install the 3 shifting keys to the clutch hub.

Install the 3 shifting key springs to the clutch hub.

Place the balls in the holes of the shifting keys and install the hub sleeve while pushing in the balls.

ПРИМЕЧАНИЕ:

Take care to prevent the balls from scattering.

Coat the 4th driven gear synchronizer ring set with gear oil.

Using SST and a press, install the No. 1 transmission clutch hub to the 4th driven gear.

SST

09309-14010

ПРИМЕЧАНИЕ:

During and after installation, make sure that the gear and synchronizer ring move smoothly.

УКАЗАНИЕ:

Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

Select a new snap ring, using the table below, that makes the thrust clearance of the No. 2 transmission clutch hub less than 0.1 mm (0.0039 in.).

Using a brass bar and hammer, tap the snap ring to the No. 1 output shaft.

ПРИМЕЧАНИЕ:

If the transmission clutch hub is not fully pressed on the shaft, or if its thrust clearance is excessive, the driven gear thrust clearance may also be excessive.

Using a feeler gauge, measure the 4th driven gear thrust clearance.

Standard clearance:

0.10 to 0.65 mm (0.0039 to 0.0256 in.)

Maximum clearance:

0.65 mm (0.0256 in.)

Using a dial indicator, measure the 4th driven gear radial clearance.

Standard clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum clearance:

0.066 mm (0.0026 in.)

Coat the 3rd driven gear synchronizer ring set with gear oil.

Install the inner ring onto the 3rd driven gear.

Install the middle ring onto the 3rd driven gear.

Install the outer ring onto the 3rd driven gear.

Coat the needle roller bearing with gear oil and install it to the No. 1 output shaft.

Install the output shaft spacer to the No. 1 output shaft.

Coat the 3rd driven gear with gear oil and install it to the No. 1 output shaft.

ПРИМЕЧАНИЕ:

After placing the gear on the shaft, make sure that the synchronizer is correctly aligned with the shifting keys on the hub.

Using SST and a press, install the output shaft rear bearing to the No. 1 output shaft.

SST

09308-14010

ПРИМЕЧАНИЕ:

During and after installation, make sure that the gear and synchronizer ring move smoothly.

УКАЗАНИЕ:

When pressing in the bearing, apply force only to the inner race. Do not apply force to the seal.

Select a new snap ring, using the table below, that makes the thrust clearance of the output shaft bearing less than 0.1 mm (0.0039 in.).

Using a snap ring expander, install the snap ring onto the No. 1 output shaft.

ПРИМЕЧАНИЕ:

If the bearing is not fully pressed on the shaft, or if its thrust clearance is excessive, the driven gear thrust clearance may also be excessive.

Using a feeler gauge, measure the 3rd driven gear thrust clearance.

Standard clearance:

0.11 to 0.54 mm (0.0043 to 0.0213 in.)

Maximum clearance:

0.54 mm (0.0213 in.)

Using a dial indicator, measure the 3rd driven gear radial clearance.

Standard clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum clearance:

0.066 mm (0.0026 in.)

ПРИМЕЧАНИЕ:

1. Support both ends of the output shaft at all times when the output shaft is mounted in a horizontal position. Failure to support both ends of the shaft will result in the shaft falling out of the vise.
   
2. Only secure the output shaft in a vice which has soft jaws. Failure to use caution when mounting or working on the output shaft can result in damage to bearings, bearing surfaces or damage to gear teeth.