Input Shaft: Disassembly

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 the specification, replace the No. 2 transaxle clutch hub, 4th gear or input shaft rear radial ball bearing.
  
  Fig 1: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance.
  Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 in.)
  
  If the clearance is out of the specification, replace the No. 2 transaxle clutch hub, 3rd gear or input shaft.
  
  Fig 2: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 4TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance.

Standard clearance

BEARING SPECIFICATION

Bearing	Specified Condition
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 the specification, replace the 4th gear, needle roller bearing or input shaft.

Fig 3: Measuring Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 3RD GEAR RADIAL CLEARANCE

Using a dial indicator, measure the gear radial clearance.

Standard clearance

BEARING SPECIFICATION

Bearing	Specified Condition
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 the specification, replace the 3rd gear, needle roller bearing or input shaft.

Fig 4: Measuring Gear Radial Clearance

REMOVE 4TH GEAR
1. Hold the input shaft assembly in a vise with soft jaws.
2. Using 2 screwdrivers and a hammer, tap out the input shaft rear bearing shaft snap ring from the input shaft.
  HINT:
  
  Cover with a piece of cloth to keep the snap ring from flying off.
  
  Fig 5: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press out the input shaft rear bearing and 4th gear.
  SST 09950-00020
  
  NOTE: Do not overtighten the SST.
  
  Fig 6: Pressing Out Input Shaft Rear Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR NEEDLE ROLLER BEARING
1. Remove the needle roller bearing from the input shaft.
  
  Fig 7: Removing Needle Roller Bearing From Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 4 SYNCHRONIZER OUTER RING
1. Remove the No. 4 synchronizer outer ring from the No. 2 transaxle clutch hub.
  
  Fig 8: Removing 2ND Synchronizer Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR BUSH
1. Remove the 4th gear bush from the No. 2 transaxle clutch hub.
  
  Fig 9: Removing 4Th Gear Bush From No. 2 Transmission Clutch Hub
  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:
  
  Cover with a piece of cloth to keep the snap ring from flying off.
  
  Fig 10: Removing No. 2 Clutch Hub Setting Shaft Snap Ring From Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press out the No. 2 transaxle clutch hub and 3rd gear from the input shaft.
  SST 09950-00020
  
  NOTE: Do not overtighten the SST.
  
  Fig 11: Pressing No. 2 Transaxle Clutch Hub And 3rd Gear Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR NEEDLE ROLLER BEARING
1. Remove the needle roller bearing from the input shaft.
  
  Fig 12: Removing Needle Roller Bearing From Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 SYNCHRONIZER RING
1. Remove the No. 3 synchronizer ring from the 3rd gear.
  
  Fig 13: Removing No. 3 Synchronizer Ring From 3Rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 TRANSAXLE HUB SLEEVE
1. Remove the No. 2 transaxle hub sleeve, 3 No. 2 synchromesh shifting keys and 3 No. 2 synchromesh shifting key springs from the No. 2 transaxle clutch hub.
  HINT:
  
  Cover with a piece of cloth to keep the shifting key and shifting key spring from flying off.
  
  Fig 14: Removing No. 2 Transmission Hub Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT FRONT BEARING
1. Using SST and a press, press out the input shaft front bearing (inner race) from the input shaft.
  NOTE: Do not overtighten SST.
  
  Fig 15: Pressing Out Input Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002