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Input Shaft: Reassembly

  1. INSTALL NO. 2 TRANSMISSION HUB SLEEVE 
    1. Coat the No. 2 transmission hub sleeve with gear oil, and install it to the No. 2 transmission clutch hub.
      NOTE: Be sure to set the No. 2 transmission hub sleeve and No. 2 transmission clutch hub in the correct orientation.
    2. Using a screwdriver, install the 3 synchromesh key springs with 3 No. 2 synchromesh shifting keys to the No. 2 transmission clutch hub.
  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING 
    1. Coat the 3rd gear needle roller bearing with gear oil, and install it to the input shaft.
      Fig 1: Installing 3rd Gear Needle Roller Bearing
      G04154771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL 3RD GEAR 
    1. Coat the 3rd gear with gear oil, and install it to the input shaft.
      Fig 2: Installing 3rd Gear
      G04154772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 2 SYNCHRONIZER RING (for 3rd Gear) 
    1. Coat the No. 2 synchronizer ring with gear oil, and install it to the 3rd gear.
      Fig 3: Installing No. 2 Synchronizer Ring
      G04154773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB 
    1. Using SST and a press, press in the No. 2 transmission clutch hub to the input shaft.

      SST 09316-60011 (09316-00021) 

      NOTE: Fit the synchromesh shifting key into the groove of the synchronizer ring correctly.
    2. Select a snap ring that will allow minimum axial play.

      Standard clearance: 0.1 mm (0.004 in.) or less 

      Fig 4: Installing No. 2 Transmission Clutch Hub
      G04154774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard snap ring thickness 

      SNAP RING SPECIFICATION

      Mark Thickness mm (in)
      0 2.30 (0.0906)
      1 2.36 (0.0929)
      2 2.42 (0.0953)
      3 2.48 (0.0976)
      4 2.54 (0.1000)
      5 2.60 (0.1024)
    3. Using a brass bar and hammer, and tap in the snap ring to the input shaft.
      Fig 5: Installing Snap Ring
      G04154775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 2 SYNCHRONIZER RING (for 4th Gear) 
    1. Coat the No. 2 synchronizer ring with gear oil, and install it to the No. 2 transmission clutch hub.
      Fig 6: Installing No. 2 Synchronizer Ring
      G04154776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL 4TH GEAR NEEDLE ROLLER BEARING 
    1. Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil, and install them to the No. 2 transmission clutch hub.
      Fig 7: Installing 4th Gear Needle Roller Bearing
      G04154777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL 4TH GEAR 
    1. Coat the 4th gear with gear oil, and install it to the input shaft.
      Fig 8: Installing 4th Gear
      G04154778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR INPUT SHAFT BEARING SHAFT SNAP RING 
    1. Using SST and a press, press in the radial ball bearing to the input shaft.

      SST 09608-04031 

    2. Select a snap ring that will allow minimum axial play.

      Standard clearance: 0.1 mm (0.004 in.) or less 

      Standard snap ring thickness 

      Fig 9: Pressing In Radial Ball Bearing To Input Shaft
      G04154779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING SPECIFICATION

      Mark Thickness mm (in)
      A 2.29 (0.0901)
      B 2.35 (0.0925)
      C 2.41 (0.0948)
      D 2.47 (0.0972)
      E 2.53 (0.0996)
      F 2.59 (0.1019)
    3. Using a brass bar and hammer, and tap in the snap ring to the input shaft.
      NOTE: Take care not to damage the journal surface of the snap ring.
      Fig 10: Tapping In Snap Ring To Input Shaft
      G04154780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT 3RD GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the radial clearance.

      Standard clearance 

      STANDARD CLEARANCE

      Item 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 0.0022 in.)

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

      Fig 11: Measuring Radial Clearance
      G04154781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT 4TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the radial clearance.

      Standard clearance 

      STANDARD CLEARANCE

      Item Specified Condition
      KOYO made 0.009 to 0.050 mm (0.0004 to 0.0020 in.)
      NSK made 0.009 to 0.050 mm (0.0004 to 0.0020 in.)
      Fig 12: Inspecting 4th Gear Radial Clearance
      G04154782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  12. 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.) 

      If the clearance is not within the specification, replace the gear, No. 2 synchronizer ring or No. 2 transmission clutch hub.

      Fig 13: Inspecting 3rd Gear Thrust Clearance
      G04154783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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.) 

      If the clearance is not within the specification, replace the gear or input shaft rear radial ball bearing.

      Fig 14: Inspecting 4th Gear Thrust Clearance
      G04154784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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