Input Shaft: Reassembly

INSTALL NO. 2 TRANSMISSION HUB SLEEVE
1. Coat the No. 2 transmission hub sleeve with gear oil, and install it onto the No. 2 transmission clutch hub.
  NOTE: Orient the No. 2 transmission hub sleeve and No. 2 transmission clutch hub correctly.
  
  Fig 1: Installing No. 2 Transmission Hub Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the 3 synchromesh key springs with 3 synchromesh shifting keys onto the No. 2 transmission clutch hub.
INSTALL 3RD GEAR NEEDLE ROLLER BEARING
1. Coat the 3rd gear needle roller bearing with gear oil and install it onto the input shaft.
  
  Fig 2: Identifying 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 onto the input shaft.
  
  Fig 3: Identifying 3Rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD GEAR SYNCHRONIZER RING
1. Coat the 3rd gear synchronizer ring with gear oil and install it onto the 3rd gear.
  
  Fig 4: Identifying 3Rd Gear Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 2 TRANSMISSION CLUTCH HUB

Using SST and a press, install the No. 2 transmission clutch hub onto the input shaft.
SST 09316-60011 (09316-00021)

NOTE: Fit the synchromesh shifting key into the groove of the synchronizer ring correctly.

Fig 5: Installing No. 2 Transmission Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring that will allow minimum axial play.

Fig 6: Checking Snap Ring Axle Play

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard clearance:

0.1 mm (0.0039 in.) or less

Snap ring thickness

THICKNESS SPECIFICATIONS

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
0	2.30 (0.0906)	3	2.48 (0.0976)
1	2.36 (0.0929)	4	2.54(0.1000)
2	2.42 (0.0953)	5	2.60(0.1024)

Using a brass bar and a hammer, install the snap ring onto the input shaft.

INSTALL 4TH GEAR SYNCHRONIZER RING
1. Coat the 4th gear synchronizer ring with gear oil and install it onto the No. 2 transmission clutch hub.
  
  Fig 7: Identifying 4Th Gear Synchronizer Ring And No. 2 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 onto the No. 2 transmission clutch hub.
  
  Fig 8: Identifying 4Th Gear Needle Roller Bearing And 4Th Gear Bearing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH GEAR
1. Coat the 4th gear with gear oil and install it onto the input shaft.
  
  Fig 9: Identifying 4Th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SHAFT REAR RADIAL BALL BEARING

Using SST and a press, install the input shaft rear radial ball bearing onto the input shaft.
SST 09608-04031

Fig 10: Installing Input Shaft Rear Radial Ball Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring that will allow minimum axial play.

Standard clearance:

0.1 mm (0.0039 in.) or less

Snap ring thickness

THICKNESS SPECIFICATIONS

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.29 (0.0901)	D	2.47 (0.0972)
B	2.35 (0.0925)	E	2.53 (0.0996)
C	2.41 (0.0948)	F	2.59(0.1019)

Fig 11: Identifying Snap Ring

Using a brass bar and a hammer, install the snap ring onto the input shaft.
NOTE: Do not damage the journal surface of the snap ring.

INSPECT 3RD GEAR RADIAL CLEARANCE
1. Using a dial gauge, measure the 3rd gear radial clearance.
  Standard clearance:
  
  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.)
  
  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 12: Measuring 3Rd Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 4TH GEAR RADIAL CLEARANCE
1. Using a dial gauge, measure the 4th gear radial clearance.
  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 13: Measuring 4Th Gear Radial 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 14: Measuring 3Rd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 15: Measuring 4Th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002