Input Shaft: Disassembly

INSPECT 4TH GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the thrust clearance.
  Standard clearance: 0.1 to 0.55 mm (0.0039 to 0.0217 in.)
  
  Maximum clearance: 0.55 mm (0.0217 in.)
  
  If the clearance is greater than the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.
  
  Fig 1: Inspecting 4th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance.
  Standard clearance: 0.1 to 0.35 mm (0.0039 to 0.0138 in.)
  
  Maximum clearance: 0.35 mm (0.0138 in.)
  
  If the clearance is greater than the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.
  
  Fig 2: Inspecting 3rd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 4TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the radial clearance between the gear and shaft.
  Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 in.)
  
  Maximum clearance: 0.050 mm (0.0020 in.)
  
  If the clearance is greater the maximum, replace the gear, needle roller bearing or shaft.
  
  Fig 3: Inspecting 4th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 3RD GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance between the gear and shaft.

Standard clearance

STANDARD CLEARANCE

Bearing	Specified Condition
KOYO made	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made	0.015 to 0.056 mm (0.0006 to 0.0022in.)

If the clearance is not within the specification, replace the gear, needle roller bearing or shaft.

Fig 4: Inspecting 3rd Gear Radial Clearance

REMOVE 4TH GEAR
1. Using 2 screwdrivers and a hammer, tap out the input shaft rear bearing shaft snap ring from the input shaft.
  HINT:
  
  Use a cloth to prevent the snap ring from springing away.
  
  Fig 5: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press out the input shaft rear radial ball bearing and 4th gear from the input shaft.
  SST 09950-00020
  NOTE:
  - Do not tighten SST excessively.
  - Support the input shaft assembly by hand so that it will not drop.
    
    Fig 6: Removing Input Shaft Rear Radial Ball Bearing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR NEEDLE ROLLER BEARING
1. Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.
  
  Fig 7: Removing 4th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 SYNCHRONIZER RING (for 4th Gear)
1. Remove the No. 2 synchronizer ring from the No. 2 transmission clutch hub.
  
  Fig 8: Removing No. 2 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR
1. Using 2 screwdrivers and a hammer, tap out the No. 2 clutch hub setting shaft snap ring from the input shaft.
  HINT:
  
  Use a cloth to prevent the snap ring from springing away.
  
  Fig 9: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, remove the No. 2 transmission clutch hub and 3rd gear from the input shaft.
  SST 09950-00020
  NOTE:
  - Do not tighten SST excessively.
  - Support the input shaft by hand so that it will not drop.
    
    Fig 10: Removing No. 2 Transmission Clutch Hub
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 SYNCHRONIZER RING (for 3rd Gear)
1. Remove the No. 2 synchronizer ring from the 3rd gear.
  
  Fig 11: Removing No. 2 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR NEEDLE ROLLER BEARING
1. Remove the 3rd gear needle roller bearing from the input shaft.
  
  Fig 12: Removing 3rd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 TRANSMISSION HUB SLEEVE
1. Remove the No. 2 transmission hub sleeve, 3 No. 2 shifting keys and 3 No. 2 shiftings key spring from the No. 2 transmission clutch hub.
  NOTE: Use a cloth to keep the shifting key and shifting key from spring springing away.
  
  Fig 13: Removing No. 2 Transmission Hub Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002