Input Shaft: Reassembly

INSTALL INPUT SHAFT FRONT BEARING
1. Using SST and a press, press in the front bearing (inner race).
  SST 09608-00071
  
  Fig 1: Pressing In Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 TRANSAXLE HUB SLEEVE
1. Coat the No. 2 transaxle hub sleeve with gear oil, and install it to the No. 2 transaxle clutch hub.
  NOTE: Set the No. 2 transaxle clutch hub sleeve and the No. 2 transaxle 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 transaxle clutch hub.
  
  Fig 2: Installing Synchromesh Key Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD GEAR NEEDLE ROLLER BEARING
1. Coat the 3rd gear bearing with gear oil, and install it to the input shaft.
  
  Fig 3: Installing 3Rd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD GEAR
1. Coat the 3rd gear with gear oil, and install it to the input shaft.
  
  Fig 4: Installing 3Rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 SYNCHRONIZER RING
1. Coat the No. 3 synchronizer ring with gear oil, and install it to the 3rd gear.
  
  Fig 5: Installing No. 3 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 2 TRANSAXLE CLUTCH HUB

Using SST and a press, press in the No. 2 transaxle clutch hub to the input shaft.
SST 09316-60011 (09316-00041)
NOTE:
- Align the claw of the No. 2 clutch hub with the notch of the No. 3 synchronizer ring and install it.
- Make sure that the 3rd gear can rotate.
  
  Fig 6: Pressing In No. 2 Transmission Clutch Hub To Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a No. 2 clutch hub setting shaft snap ring so that the clearance between the No. 2 transaxle clutch hub and the No. 2 clutch hub setting shaft snap ring will be within the 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: Installing No. 2 Clutch Hub Setting Shaft Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

THICKNESS CHART

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.)

INSTALL 4TH GEAR BUSH
1. Coat the 4th gear bush with gear oil, and install it to the input shaft.
  
  Fig 8: Installing 4Th Gear Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 4 SYNCHRONIZER OUTER RING
1. Coat the No. 4 synchronizer outer ring with gear oil, and install it to the No. 2 transaxle clutch hub.
  NOTE: Align the claw of the No. 2 clutch hub with the notch of the No. 4 synchronizer outer ring and install it.
  
  Fig 9: Installing 2Nd Synchronizer Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH GEAR NEEDLE ROLLER BEARING
1. Coat the needle roller bearing with gear oil, and install it to the input shaft.
  
  Fig 10: Installing 4Th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH GEAR
1. Coat the 4th gear with gear oil, and install it to the input shaft.
  
  Fig 11: Installing 4Th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SHAFT REAR RADIAL BALL BEARING

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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 the 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

THICKNESS CHART

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.)

Fig 13: Installing Rear Bearing Shaft Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 3RD GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance.

Standard clearance

THICKNESS CHART

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 14: Measuring Radial Clearance

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 15: Measuring Radial Clearance

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 16: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 17: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002