Input Shaft: Disassembly

INSPECT 4TH GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 4th gear 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 exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.
  
  Fig 1: Measuring 4Th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a dial gauge, measure the 3rd gear 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 exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.
  
  Fig 2: Measuring 3Rd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 4TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 4th gear 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 exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.
  
  Fig 3: Measuring 4Th Gear Radial Clearance Between Gear And Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR RADIAL CLEARANCE
1. Using a dial gauge, measure the 3rd gear radial clearance between the gear and shaft.
  Standard clearance:
  
  KOYO made bearing:
  
  0.015 to 0.058 mm (0.0006 to 0.0023 in.)
  
  NSK made bearing:
  
  0.015 to 0.056 mm (0.0006 to 0.0022 in.)
  
  Maximum clearance:
  
  KOYO made:
  
  0.058 mm (0.0023 in.)
  
  NSK made:
  
  0.056 mm (0.0022 in.)
  
  If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.
  
  Fig 4: Measuring 3Rd Gear Radial Clearance Between Gear And Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR
1. Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.
  HINT:
  
  Use a piece of cloth to keep the snap ring from flying off.
  
  Fig 5: Removing Input Shaft Rear Bearing Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, remove the input shaft rear radial ball bearing and 4th gear from the input shaft.
  SST 09950-00020
  
  HINT:
  - Do not tighten SST excessively.
  - Support the input shaft assembly by hand to prevent it from dropping off.
    
    Fig 6: Identifying 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: Identifying 4Th Gear Needle Roller Bearing And 4Th Gear Bearing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR SYNCHRONIZER RING
1. Remove the No. 2 synchronizer ring from the No. 2 transmission clutch hub.
  
  Fig 8: Identifying No. 2 Synchronizer Ring And No. 2 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR
1. Using 2 screwdrivers and a hammer, remove the clutch hub No. 2 setting shaft snap ring from the input shaft.
  HINT:
  
  Use a piece of cloth to keep the snap ring from flying off.
  
  Fig 9: Removing 3Rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, remove the No. 2 transmission clutch hub and the 3rd gear from the input shaft.
  SST 09950-00020
  NOTE:
  - Do not tighten SST excessively.
  - Support the input shaft by hand to prevent it from dropping off.
    
    Fig 10: Removing No. 2 Transmission Clutch Hub With SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR SYNCHRONIZER RING
1. Remove the No. 2 synchronizer ring from the 3rd gear.
  
  Fig 11: Removing 3Rd Gear 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: Identifying 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, the 3 shifting keys and 3 shifting key springs from the No. 2 transmission clutch hub.
  NOTE: Use a shop rag or piece of cloth to keep the shifting key and shifting key spring from flying off.
  
  Fig 13: Removing No. 2 Transmission Hub Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002