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Input Shaft: Installation

  1. INSTALL FRONT INPUT SHAFT BEARING 
    1. Using SST and a press, press in the front bearing (inner race).

    SST 09608-00071 

    Fig 1: Pressing In Front Bearing (Inner Race)
    G05388971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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: Set the No. 2 transmission clutch hub sleeve and the No. 2 transmission clutch hub in the correct orientation.
    2. Using a screwdriver, install the 3 synchromesh key springs with the 3 synchromesh shifting keys to the No. 2 transmission clutch hub.
    Fig 2: Identifying Synchromesh Key Springs
    G05539808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL 3RD GEAR NEEDLE ROLLER BEARING 
    1. Coat the 3rd gear bearing with gear oil, and install it to the input shaft.
    Fig 3: Identifying 3rd Gear Needle Roller Bearing
    G05539809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL 3RD GEAR 
    1. Coat the 3rd gear with gear oil, and install it to the input shaft.
    Fig 4: Identifying 3rd Gear And Input Shaft
    G05388974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 3 SYNCHRONIZER RING 
    1. Coat the No. 3 synchronizer ring with gear oil, and install it to the 3rd gear.
    Fig 5: Identifying No. 3 Synchronizer Ring
    G05539811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 2 TRANSMISSION CLUTCH HUB 
    1. Using SST and a press, press in the No. 2 transmission clutch hub to the input shaft.
      NOTE:
      • Align the claw of the No. 2 clutch hub with the notch of the No. 3 synchronizer ring and install them.
      • Make sure that the 3rd gear can rotate.
      Fig 6: Pressing In No. 2 Transmission Clutch Hub To Input Shaft
      G05388976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a No. 2 clutch hub setting shaft snap ring so that the clearance between the No. 2 transmission clutch hub and the No. 2 clutch hub setting shaft snap ring will be within specification. Using a brass bar and hammer, install the No. 2 clutch hub setting shaft snap ring.

      Standard clearance: 

      0.1 mm (0.004 in.) or less 

      Standard snap ring thickness 

      Fig 7: Identifying No. 2 Clutch Hub Setting Shaft Snap Ring
      G05388977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS SPECIFICATION

      Part No. Mark Thickness
      90520-34003 H 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      90520-34004 J 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
      90520-34005 K 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      90520-34006 L 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      90520-34007 M 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
      90520-34008 N 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
      90520-34009 P 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
  7. INSTALL 4TH GEAR BUSH 
    1. Coat the 4th gear bush with gear oil, and install it to the input shaft.
    Fig 8: Identifying 4th Gear Bush
    G05388978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL 2ND SYNCHRONIZER OUTER RING 
    1. Coat the 2nd synchronizer outer ring (No. 4 synchronizer ring) with gear oil, and install it to the No. 2 transmission clutch hub.
    NOTE: Align the claw of the No. 2 clutch hub with the notch of the 2nd synchronizer outer ring (No. 4 synchronizer ring) and install it.
    Fig 9: Identifying 2nd Synchronizer Outer Ring
    G05388979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL 4TH GEAR NEEDLE ROLLER BEARING 
    1. Coat the needle roller bearing with gear oil, and install it to the input shaft.
    Fig 10: Identifying 4th Gear Needle Roller Bearing
    G05388980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL 4TH GEAR 
    1. Coat the 4th gear with gear oil, and install it to the input shaft.
    Fig 11: Identifying 4th Gear
    G05388981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR INPUT SHAFT RADIAL BALL 
    1. Using SST and a press, press in the rear radial ball bearing to the input shaft.

      SST 09608-06041 

      NOTE:
      • Install the bearing with its groove for the snap ring facing upward.
      • Make sure that the 3rd gear rotates.
      Fig 12: Pressing In Rear Radial Ball Bearing To Input Shaft
      G05388982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a rear bearing shaft snap ring so that the clearance between the rear radial ball bearing and the rear bearing shaft snap ring will be within specification. Using a brass bar and hammer, install the rear bearing shaft snap ring.

    Standard clearance: 

    0.1 mm (0.004 in.) or less 

    Standard snap ring thickness 

    Fig 13: Identifying Rear Bearing Shaft Snap Ring
    G05388983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    SNAP RING THICKNESS SPECIFICATION

    Part No. Mark Thickness
    90520-30008 1 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
    90520-30009 2 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
    90520-30010 3 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
    90520-30011 4 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
    90520-30012 5 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
    90520-30013 6 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
    90520-30021 7 2.65 to 2.70 mm (0.1043 to 0.1063 in.)
    90520-30022 8 2.70 to 2.75 mm (0.1063 to 0.1083 in.)
  12. INSPECT 3RD GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the radial clearance.

    Standard clearance 

    RADIAL CLEARANCE SPECIFICATION

    Bearing Standard Clearance
    KOYO made 0.009 to 0.053 mm (0.0004 to 0.0021 in.)
    NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.)

    If the clearance is out of specification, replace the 3rd gear, needle roller bearing or input shaft.

    Fig 14: Measuring Radial Clearance
    G05388984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT 4TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the radial clearance.

    Standard clearance 

    RADIAL CLEARANCE SPECIFICATION

    Bearing Standard Clearance
    KOYO made 0.009 to 0.053 mm (0.0004 to 0.0021 in.)
    NSK made 0.009 to 0.051 mm (0.0004 to 0.0020 in.)

    If the clearance is out of specification, replace the 4th gear, needle roller bearing or input shaft.

    Fig 15: Measuring Radial Clearance
    G05388985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT 3RD GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance.

    Standard clearance: 

    0.10 to 0.35 mm (0.0039 to 0.0138 in.) 

    If the clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.

    Fig 16: Measuring Thrust Clearance
    G05388986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT 4TH GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the thrust clearance.

    Standard clearance: 

    0.10 to 0.57 mm (0.0039 to 0.0224 in.) 

    If the clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.

    Fig 17: Measuring Thrust Clearance
    G05539823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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