Toyota Camry Quiz
Manual transmission/transaxle

Output shaft assy (E351)

In this manual: Manual transmission/transaxle
Introduction — 61Audio & visual system — 16Automatic transmission / trans — 19Transmission revolution (ATM) — 1Shift lock system (ATM) — 1Brake — 20Clutch — 10Communication system — 4Cooling — 15Cruise control — 3Drive shaft / propeller shaft — 9Emission control — 8Engine control system — 12Engine hood/door — 7Exhaust — 3Exterior/interior trim — 14Front suspension — 9Fuel — 12Heater & air conditioner — 16Ignition — 8Instrument panel/meter — 7Intake — 7Lighting — 11Lubrication — 16Manual transmission/transaxle — 13Parking brake — 10Power steering — 7Rear suspension — 10Seat — 12Service specifications — 26Sliding roof/convertible — 4Starting & charging — 11Starting system (2AZ−FE)(From July, 2003) — 1Starting system (1MZ−FE/3MZ−FE) — 1Steering column — 6Theft deterrent & door lock — 9Tire & wheel — 4Windshield/windowglass/mirror — 5Back window glass — 1Power window control system — 1Power mirror control system — 1Inner rear view mirror assy — 1Windshield glass — 1Wiring — 1
4steps
~24min
2/5difficulty
Done 0 of 4
OVERHAUL 1. INSPECT 1ST GEAR THRUST CLEARANCE a. Using a feeler gauge, measure the 1st gear thrust clearance.Standard clearance: 0.25 to 0.40 mm (0.0098 to 0.0157 in.) Inspect 1st gear thrust clearance Inspect 1st gear thrust clearance 2. INSPECT 2ND GEAR THRUST CLEARANCE a. Using a dial indicator, measure the 2nd gear thrust clearance.Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 in.) Inspect 2nd gear thrust clearance Inspect 2nd gear thrust clearance 3. INSPECT 1ST GEAR RADIAL CLEARANCE

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

Standard clearance: mm (in.)
If the clearance is out of the specification, replace the 1st gear

If the clearance is out of the specification, replace the 1st gear needle roller bearing.

Inspect 1st gear radial clearance Inspect 1st gear radial clearance 4. INSPECT 2ND GEAR RADIAL CLEARANCE

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

Standard clearance: mm (in.)
If the clearance is out of the specification, replace the 2nd gear

If the clearance is out of the specification, replace the 2nd gear needle roller bearing.

Inspect 2nd gear radial clearance Inspect 2nd gear radial clearance 5. REMOVE 4TH DRIVEN GEAR a. Using SST and a press, remove the output shaft bearing rear (inner race) and 4th driven gear.

SST 09950−00020

Remove 4th driven gear Remove 4th driven gear 6. REMOVE OUTPUT GEAR SPACER

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

Remove output gear spacer Remove output gear spacer 7. REMOVE 2ND GEAR a. Using SST and a press, remove the 3rd driven gear and 2nd gear from the out put shaft.

SST 09950−00020

Remove 2nd gear Remove 2nd gear 8. REMOVE SYNCHRONIZER RING SET No.2

a. Remove the synchronizer ring set No.2 from the transmission clutch hub No.1.

Remove synchronizer ring set No.2 Remove synchronizer ring set No.2 9. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

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

Remove 2nd gear needle roller bearing Remove 2nd gear needle roller bearing 10. REMOVE 2ND GEAR BEARING SPACER

a. Remove the 2nd gear bearing spacer from the output shaft.

Remove 2nd gear bearing spacer Remove 2nd gear bearing spacer 11. REMOVE 2ND GEAR BUSH

a. Remove the 2nd gear bush from the output shaft.

Remove 2nd gear bush Remove 2nd gear bush 12. REMOVE 2ND GEAR BUSH BALL

a. Using a magnetic finger, remove the 2nd gear bush ball from the output sha

Remove 2nd gear bush ball Remove 2nd gear bush ball 13. REMOVE 1ST GEAR a. Using SST and a press, remove the transmission clutch hub No.1 and 1st gear from the output shaft.

SST 09950−00020

Remove 1st gear Remove 1st gear 14. REMOVE SYNCHRONIZER RING SET No.1

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

Remove synchronizer ring set No.1 Remove synchronizer ring set No.1 15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

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

Remove 1st gear needle roller bearing Remove 1st gear needle roller bearing 16. REMOVE OUTPUT SHAFT FRONT BEARING a. Using SST and a press, remove the output shaft front bearing (inner race) from the output shaft.

SST 09950−00020, 09950−60010 (09951−00320), 09950−70010 (09951−07150)

NOTICE: Do not tighten SST excessively. Remove output shaft front bearing Remove output shaft front bearing 17. REMOVE REVERSE GEAR

a. Remove the reverse gear, 3 synchromesh shifting keys and 3 synchromesh shifting key springs from the transmission clutch hub No.1.

Remove reverse gear Remove reverse gear 18. INSPECT OUTPUT SHAFT a. Using V−block and a dial indicator, measure the shaft run out.Maximum run out: 0.03 mm (0.0012 in.)

If the run out exceeds the maximum, replace the input shaft.

b. Using a micrometer, measure the outer diameter of the
b. Using a micrometer, measure the outer diameter of the output shaft journal surface.Outer diameter: mm (in.)
If the outer diameter is less than the minimum, replace the input

If the outer diameter is less than the minimum, replace the input shaft.

19. INSPECT 2ND GEAR
19. INSPECT 2ND GEAR

a. Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Inside diameter: mm (in.)
If the inside diameter exceeds the maximum, replace the 2nd

If the inside diameter exceeds the maximum, replace the 2nd gear.

Inspect 2nd gear Inspect 2nd gear 20. INSPECT 1ST GEAR

a. Using a cylinder gauge, measure the inside diameter of the 1st gear.

Inside diameter: mm (in.)
If the inside diameter exceeds the maximum, replace the 1st

If the inside diameter exceeds the maximum, replace the 1st gear.

Inspect 1st gear Inspect 1st gear 21. INSPECT SYNCHRONIZER RING SET No.2

a. Coat the cone of the 2nd gear with gear oil, check that it does not turn in the both circumference directions while pushing it to the synchronizer ring No.2.

Inspect synchronizer ring set No.2 Inspect synchronizer ring set No.2 b. Check the clearance between the synchronizer ring No.2 and 2nd gear while pushing it to the synchronizer ring No.2.Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 in.)

If the standard clearance is out of the specification, replace the synchronizer ring set No.2 Ωith a new one.

22. INSPECT SYNCHRONIZER RING SET No.1
22. INSPECT SYNCHRONIZER RING SET No.1

a. Coat the 1st gear cone with gear oil. Turn the synchronizer ring set No.1. in one direction while pushing it to the 1st gear cone. Check that the ring locks.

b. Check the clearance between the synchronizer ring set
b. Check the clearance between the synchronizer ring set No.1 and 1st gear while pushing it to the cone of synchronizer ring set No.1.Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 in.)

If the standard clearance is out of the specification, replace the synchronizer ring set No.1 Ωith a new one.

23. INSPECT REVERSE GEAR
23. INSPECT REVERSE GEAR a. Using a vernier calipers, measure the reverse gear groove and thickness of the claw part on gear shift fork No.1, and calculate Standard clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 in.) {A − B}

If the clearance is out of the specification, replace the reverse gear and gear shift fork No.1 Ωith the new one.

Inspect reverse gear Inspect reverse gear 24. INSPECT TRANSMISSION CLUTCH HUB No.1
  1. Check the sliding condition between the transmission clutch hub No.1 and reverse gear.
  2. Check the tip of spline gear on the sleeve of reverse gear for wear.
Inspect transmission clutch hub No.1 Inspect transmission clutch hub No.1 25. INSTALL REVERSE GEAR
  1. Coat the reverse gear with gear oil.
  2. Install the 3 synchromesh shifting key spring No.1 and transmission clutch hub No.1 to the reverse gear.
NOTICE: Do not set the reverse gear and the transmission clutch hub No.1 in the incorrect direction.

c. Using a screwdriver, install the synchromesh shifting key No.1 to the reverse gear.

Install reverse gear Install reverse gear 26. INSTALL OUTPUT SHAFT FRONT BEARING a. Using SST and a press, install the output shaft front bearing (inner race) to the output shaft.

SST 09950−60010 (09951−00430), 09950−70010 (09951−07150)

Install output shaft front bearing Install output shaft front bearing 27. INSTALL SYNCHRONIZER RING SET No.1

a. Coat the synchronizer ring set No.1 Ωith gear oil, install it to the 1st gear.

NOTICE: Align the synchronizer ring set No.1 Ωith the hole of 1st gear and install. Install synchronizer ring set No.1 Install synchronizer ring set No.1 28. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

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

Install 1st gear needle roller bearing Install 1st gear needle roller bearing 29. INSTALL 1ST GEAR

a. Coat the 1st gear with gear oil, install it to the output shaft.

Install 1st gear Install 1st gear 30. INSTALL TRANSMISSION CLUTCH HUB No.1 a. Using SST and a press, install transmission clutch hub No.1 to the output shaft.

SST 09316−60011 (09316−00031), 09950−60010 (09951−00320), 09950−70010 (09951−07100)

NOTICE:
  • Align the synchronizer ring No.1 Ωith synchromesh shifting key No.1 and install.
  • Make sure that the 1st gear rotates.
Install transmission clutch hub No.1 Install transmission clutch hub No.1 31. INSTALL 2ND GEAR BUSH BALL

a. Coat the gear bush with MP grease, install it to the output shaft.

Install 2nd gear bush ball Install 2nd gear bush ball 32. INSTALL 2ND GEAR BUSH

a. Coat the 2nd gear bush with gear oil, install it to the output shaft.

Install 2nd gear bush Install 2nd gear bush 33. INSTALL 2ND GEAR BEARING SPACER

a. Coat the 2nd gear bearing spacer with gear oil, install it to the output shaft.

Install 2nd gear bearing spacer Install 2nd gear bearing spacer 34. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

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

Install 2nd gear needle roller bearing Install 2nd gear needle roller bearing 35. INSTALL SYNCHRONIZER RING SET No.2

a. Coat the synchronizer ring set No.2 Ωith gear oil, install it to the transmission clutch hub No.1

NOTICE: Align the key groove on the synchronizer ring set No.2 Ωith the synchromesh shifting key No.1. Install synchronizer ring set No.2 Install synchronizer ring set No.2 36. INSTALL 2ND GEAR

a. Coat the 2nd gear with gear oil, install it to the output shaft.

Install 2nd gear Install 2nd gear 37. INSTALL 3RD DRIVEN GEAR a. Using SST and a press, install the 3rd driven gear to the output shaft.

SST 09608−00071, 09950−60010 (09951−00320), 09950−70010 (09951−07100)

Install 3rd driven gear Install 3rd driven gear 38. INSTALL OUTPUT GEAR SPACER

a. Install the output gear spacer to the output shaft.

Install output gear spacer Install output gear spacer 39. INSTALL 4TH DRIVEN GEAR a. Using SST and a press, install the 4th driven gear to the output shaft.

SST 09608−00071, 09950−60010 (09951−00320), 09950−70010 (09951−07100)

Install 4th driven gear Install 4th driven gear 40. INSTALL OUTPUT SHAFT FRONT BEARING a. Using SST and a press, install the output shaft front bearing (inner race) to the output shaft.

SST 09506−30012, 09950−60010 (09951−00320), 09950−70010 (09951−07100)

Install output shaft front bearing Install output shaft front bearing 41. INSPECT 2ND GEAR RADIAL CLEARANCE

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

Standard clearance: mm (in.)
If the clearance is out of the specification, replace the 2nd gear

If the clearance is out of the specification, replace the 2nd gear needle roller bearing.

Inspect 2nd gear radial clearance Inspect 2nd gear radial clearance 42. INSPECT 1ST GEAR RADIAL CLEARANCE

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

Standard clearance: mm (in.)
If the clearance is out of the specification, replace the 1st gear

If the clearance is out of the specification, replace the 1st gear needle roller bearing.

Inspect 1st gear radial clearance Inspect 1st gear radial clearance 43. INSPECT 2ND GEAR THRUST CLEARANCE a. Using a dial indicator, measure the 2nd gear thrust clearance.Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 in.) Inspect 2nd gear thrust clearance Inspect 2nd gear thrust clearance 44. INSPECT 1ST GEAR THRUST CLEARANCE a. Using a feeler gauge, measure the 1st gear thrust clearance.Standard clearance: 0.25 to 0.40 mm (0.0098 in. to 0.0157 in.) Inspect 1st gear thrust clearance Inspect 1st gear thrust clearance

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