Eb61 Manual Transaxle. Output Shaft Reassembly

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

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

Output Shaft -- Reassembly

1. INSTALL FRONT OUTPUT SHAFT BEARING

Using SST and a press, press a new front output shaft bearing onto the output shaft.
SST
09527-21011
09608-06041

2. INSTALL 1ST GEAR BUSH

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

Coat the 1st gear bush with gear oil and install it to the output shaft.

3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

Coat the 1st gear needle roller bearing with gear oil and install it to the output shaft.

4. INSTALL 1ST GEAR

Coat the 1st gear with gear oil and install it to the output shaft.
NOTICE:
Install the 1st gear as shown in the illustration.

5. INSTALL NO. 1 SYNCHRONIZER RING SET (for 1st Gear)

Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

Install the inner ring to the 1st gear.

Install the middle ring to the 1st gear.
NOTICE:
Attach the claws of the middle ring to the grooves of the 1st gear.

Install the outer ring to the 1st gear.
NOTICE:
Align the claws of the inner ring with the grooves of the outer ring before installing the outer ring.

6. INSTALL NO. 1 TRANSMISSION CLUTCH HUB

Install the No. 1 transmission clutch hub to the output shaft.
NOTICE:
Align the cutout of the No. 1 transmission clutch hub with the protrusion of the outer ring as shown in the illustration.

7. INSTALL NO. 1 SYNCHROMESH SHIFTING KEY

Install the 3 No. 1 synchromesh shifting keys to the No. 1 transmission clutch hub.

8. INSTALL REVERSE GEAR

Coat the reverse gear and No. 1 transmission clutch hub with gear oil.

Install the reverse gear to the No. 1 transmission clutch hub assembly.
NOTICE:
Install the reverse gear as shown in the illustration.

9. INSTALL NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)

Coat the 2nd gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

Install the outer ring to the No. 1 transmission clutch hub.
NOTICE:
Align the protrusion of the outer ring with the cutout of the No. 1 transmission clutch hub before installing the outer ring.

Install the middle ring to the outer ring.

Install the inner ring to the middle ring.
NOTICE:
Align the cutouts of the outer ring with the protrusions of the inner ring before installing the inner ring.
Text in Illustration
*1
Cutout
*2
Inner Ring
*3
Outer Ring

Text in Illustration
*1	Cutout
*2	Inner Ring
*3	Outer Ring

10. INSTALL INNER 2ND GEAR BEARING RACE

Coat the inner 2nd gear bearing race with gear oil and install it to the output shaft.

11. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

Coat the 2nd gear needle roller bearing with gear oil and install it to the output shaft.

12. INSTALL 2ND GEAR

Coat the 2nd gear with gear oil and install it to the output shaft.
NOTICE:
Align the claw of the middle ring with the groove of the 2nd gear before installing the 2nd gear.
Text in Illustration
*1
Groove
*2
Claw

Text in Illustration
*1	Groove
*2	Claw

13. INSTALL 3RD DRIVEN GEAR

Using SST and a press, press the 3rd driven gear onto the output shaft.
SST
09316-20011
09950-60010(09951-00180,09951-00340,09952-06010)
09950-40011(09957-04010)

14. INSTALL OUTPUT GEAR SPACER

Install the output gear spacer to the output shaft.

15. INSTALL 4TH DRIVEN GEAR

Using SST and a press, press the 4th driven gear onto the output shaft.
SST
09316-60011(09316-00011)

16. INSTALL 5TH DRIVEN GEAR

Using SST and a press, press the 5th driven gear onto the output shaft.
SST
09316-60011(09316-00011)

17. INSTALL OUTPUT GEAR SPACER

Install the output gear spacer to the output shaft.

18. INSTALL 6TH DRIVEN GEAR

Using SST and a press, press the 6th driven gear onto the output shaft.
SST
09316-60011(09316-00011)

19. INSTALL REAR OUTPUT SHAFT BEARING

Using SST and a press, press a new rear output shaft bearing onto the output shaft.
SST
09608-04031

20. INSPECT 2ND GEAR RADIAL CLEARANCE

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.

21. INSPECT 1ST GEAR RADIAL CLEARANCE

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.

22. INSPECT 2ND GEAR THRUST CLEARANCE

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.

23. INSPECT 1ST GEAR THRUST CLEARANCE

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.