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Home >> Toyota Truck >> 2005 >> Tacoma PreRunner L4-2.7L (2TR-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Overhaul (Transmission) >> Part 2

Part 2

Overhaul Continued





34. REMOVE SPEEDOMETER DRIVE (MTM) GEAR (R155 TRANSMISSION)
a. Using snap ring pliers, remove the snap ring.
b. Remove the speedometer driver gear and ball.
c. Using a magnetic finger, remove the steel ball.
d. Using snap ring pliers, remove the snap ring.





35. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING
a. Using 2 screwdrivers and a hammer, remove the output shaft bearing shaft snap ring from the output shaft.





36. REMOVE OUTPUT SHAFT REAR BEARING
a. Using SST, remove the output shaft rear bearing and output shaft spacer from the output shaft.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04051, 09957-04010, 09958-04011)





37. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)





38. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the radial clearance of the counter shaft 5th gear.
Standard clearance: 0.015 to 0.068 mm (0.0059 to 0.0027 inch)
If the clearance is not within the specified values, replace the counter 5th gear bearing with a new one.





39. REMOVE COUNTER GEAR REAR SHAFT SNAP RING
a. Using 2 screwdrivers and a hammer, remove the counter gear rear shaft snap ring from the counter gear.





40. REMOVE GEAR SPLINE PIECE NO.5
a. Using SST, remove the gear spline piece No.5 from the counter gear.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010)





41. REMOVE SYNCHRONIZER RING OUTER NO.3
a. Remove the synchronizer ring outer No.3 from the counter gear.





42. REMOVE COUNTERSHAFT 5TH GEAR
a. Remove the counter shaft 5th gear and transmission hub sleeve No.3 assy from the counter gear.





43. REMOVE COUNTER 5TH GEAR BEARING
a. Remove the counter 5th gear bearing from the counter 5th gear.





44. REMOVE TRANSMISSION HUB SLEEVE NO.3
a. Using a snap ring expander, remove the snap ring.





b. Remove the transmission hub sleeve No.3, 2 synchromesh shifting keys No.3 and 2 synchromesh shifting key springs No.3 from the counter shaft 5th gear.





45. REMOVE 5TH GEAR THRUST WASHER
a. Remove the 5th gear thrust washer from the counter gear.





46. REMOVE 5TH GEAR THRUST WASHER PIN
a. Remove the 5th gear thrust washer pin from the counter gear.





47. REMOVE OUTPUT SHAFT REAR BEARING (MTM) RETAINER
a. Remove the 4 bolts and output shaft rear bearing retainer from the intermediate plate.





48. REMOVE REVERSE IDLER GEAR SUB-ASSY
a. Pull out the reverse idler gear shaft to the rear side and remove the reverse idler gear from the intermediate plate.





49. REMOVE COUNTER SHAFT CENTER BEARING
a. Using a snap ring expander, remove the snap ring.





b. Using SST, remove the counter shaft center bearing from the intermediate plate.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011)

HINT: Remove the bearing while tapping the tip of the counter gear so that the counter gear assy is not pushed forward into the side wall of the output shaft gear.





50. REMOVE COUNTER GEAR ASSY
a. Remove the counter gear assy from the intermediate plate.





51. REMOVE INPUT SHAFT ASSY
a. Remove the input shaft assy and synchronizer ring No.2 from the output shaft.

NOTICE: Do not drop the input shaft bearing and synchronizer ring No.2.





52. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING
a. Using a snap ring expander, remove the output shaft bearing shaft snap ring from the output shaft.





53. REMOVE OUTPUT SHAFT ASSY
a. Using a plastic hammer, remove the output shaft assy by tapping the intermediate plate.





54. INSPECT SYNCHRONIZER RING OUTER NO.3
a. Apply gear oil to the cone part of gear spline piece No.5, and check that it does not turn in both directions while pushing the synchronizer ring outer No.3 to the gear spline piece No.5.
If it turns, replace the synchronizer ring.





b. Measure the clearance between the synchronizer ring outer No.3 and gear spline piece No.5 while pushing the synchronizer ring outer No.3 to the cone part of the gear spline piece No.5.
Standard clearance: 0.68 to 1.32 mm (0.0267 to 0.0610 inch)
If the clearance is not within the specified values, replace synchronizer ring outer No.3 with a new one.





55. INSPECT TRANSMISSION HUB SLEEVE NO.3
a. Check that the counter shaft 5th gear and transmission hub sleeve No.3 slide smoothly each other.
b. Check the tip of the spline gear of the transmission hub sleeve No.3 for wear.
If there are any detects, replace the transmission hub sleeve No.3.





c. Using vernier calipers, measure the transmission hub sleeve No.3 groove and the thickness of the claw part of the shift fork No.3 to calculate the clearance.
Standard clearance: 0.26 to 0.84 mm (0.0102 to 0.0331 inch)
If the clearance is not within the specified values, replace the transmission hub sleeve No.3 and shift fork No.3 with new ones.





56. INSPECT COUNTERSHAFT 5TH GEAR
a. Using a cylinder gauge, measure the inner diameter of the counter 5th gear.
Standard diameter: 38.015 to 38.040 mm (1.4967 to 1.4976 inch)
Maximum diameter: 38.040 mm (1.4976 inch)
If the diameter greater than the maximum, replace the counter shaft 5th gear with a new one.





57. INSPECT REVERSE IDLER GEAR SUB-ASSY
a. Using a caliper gauge, measure the inner diameter of the reverse idler gear.
Standard diameter: 24.040 to 24.061 mm (0.9465 to 0.9473 inch)
Maximum diameter: 24.061 mm (0.9473 inch)
If the clearance is greater than the maximum, replace the reverse idler gear with a new one.
b. Using a micrometer, measure the outer diameter of the sliding part of the reverse idler gear on the reverse idler gear shaft.
Standard diameter: 23.979 to 24.000 mm (0.9441 to 0.9449 inch)
Minimum diameter: 23.979 mm (0.9441 inch)
If the diameter is outside the specification, replace the reverse idler gear shaft with a new one.
c. Subtract the reverse idler gear shaft inside diameter measurement from the reverse idler gear diameter clearance.
Standard clearance: 0.040 to 0.082 mm (0.0016 to 0.0032 inch)
If the clearance is not as specified, replace the reverse idler gear or reverse idler gear shaft.





d. Using a feeler gauge, measure the thrust clearance of the shoe part between the reverse idler gear and the reverse shift arm.
Standard clearance: 0.05 to 0.35 mm (0.0020 to 0.0138 inch)
If the clearance is outside the specification, replace the idler gear and reverse shift arm with new ones.





58. INSTALL OUTPUT SHAFT ASSY
a. Apply gear oil to the sliding part of the output assy.
b. Using a plastic hammer, install the output shaft assy by tapping the intermediate plate.





59. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING
a. Using a snap ring expander, install the output shaft bearing shaft snap ring onto the output shaft.





60. INSTALL INPUT SHAFT ASSY
a. Apply gear oil to the input shaft assy and synchronizer ring No.2, and install them onto the output shaft.

NOTICE:
^ Install the synchronizer ring No.2 so that its groove fits into the synchromesh shifting key No.2.
^ Check that the input shaft assy rotates smoothly.





61. INSTALL COUNTER GEAR ASSY
a. Provisionally install the counter gear assy onto the intermediate plate.





62. INSTALL COUNTER SHAFT CENTER BEARING
a. Using SST and a hammer, install the new counter shaft center bearing onto the intermediate plate.
SST 09316-60011 (09316-00011)

HINT: Remove the bearing while tapping the tip of the counter gear so that the counter gear assy is not pushed forward into the side wall of the output shaft gear.





63. INSTALL REVERSE IDLER GEAR SUB-ASSY
a. Apply gear oil to each sliding part of the reverse idler gear and the reverse idler gear shaft, and install them onto the intermediate plate.

NOTICE: Orient the groove side of the reverse idler shaft to the rear side and install it from the rear side.





64. INSTALL OUTPUT SHAFT REAR BEARING (MTM) RETAINER
a. Install the output shaft rear bearing retainer into the groove of the reverse idler gear shaft with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





65. INSTALL 5TH GEAR THRUST WASHER PIN
a. Apply MP grease to the 5th gear thrust washer pin, and install it onto the counter gear.





66. INSTALL 5TH GEAR THRUST WASHER
a. Apply gear oil to the 5th gear thrust washer, and install it onto the counter gear.

NOTICE: Install the thrust washer so that its chamfer side faces to the front side.





67. INSTALL TRANSMISSION HUB SLEEVE NO.3
a. Apply gear oil to the sliding part of transmission hub sleeve No.3, and install it onto the counter shaft 5th gear.

NOTICE: Make sure that the transmission hub sleeve No.3 and counter 5th gear are oriented in the correct direction.

b. Install the 2 synchromesh shifting keys No.3 and the 2 synchromesh shifting key springs onto the counter shaft 5th gear.





c. Using a snap ring expander, install the bearing shaft snap ring onto the counter 5th gear.





68. INSTALL COUNTER 5TH GEAR BEARING
a. Apply gear oil to the counter 5th gear bearing and install it onto the counter 5th gear.





69. INSTALL COUNTERSHAFT 5TH GEAR
a. Apply gear oil to the counter 5th gear and transmission hub sleeve No.3 assy, and install them onto the counter gear.





70. INSTALL SYNCHRONIZER RING OUTER NO.3
a. Apply gear oil to the synchronizer ring outer No.3, and install it onto the counter gear.

NOTICE: Install the synchronizer ring outer No.3 so that its groove fits into the synchromesh shifting key No.3.





71. INSTALL GEAR SPLINE PIECE NO.5
a. Using SST and a press, install the gear spline piece No.5 onto the counter gear.
SST 09316-60011 (09316-00011)

NOTICE: Check that the gear rotates smoothly.





72. INSTALL COUNTER GEAR REAR SHAFT SNAP RING
a. Select the counter gear rear shaft snap ring so that the thrust gap between gear spline piece No.5 and counter gear rear shaft snap ring is within the specified values, and using a brass bar and a hammer, install it onto the counter gear.





Standard clearance: 0.1 mm (0.0039 inch) or less





73. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE
a. Using a feeler gauge, check the thrust clearance of the counter 5th gear.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)





74. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, check the counter 5th gear radial clearance.
Standard clearance: 0.015 to 0.068 mm (0.0006 to 0.0027 inch)
If the clearance is out of specification the counter 5th gear bearing.





75. INSTALL OUTPUT SHAFT REAR BEARING
a. Using SST and a press, install the new spacer and output shaft rear bearing onto the output shaft.
SST 09309-35010
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