Input Shaft: Disassembly: Disassembly

INSPECT 4TH GEAR THRUST CLEARANCE

Fig 1: Measuring Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
INSPECT 3RD GEAR THRUST CLEARANCE

Fig 2: Measuring Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

INSPECT 4TH GEAR RADIAL CLEARANCE

Fig 3: Measuring Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a dial indicator, measure the radial clearance.

Standard clearance

Bearing	Specified Condition
JTEKT made	0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made	0.009 to 0.051mm (0.0004 to 0.0020 in.)

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

INSPECT 3RD GEAR RADIAL CLEARANCE

Fig 4: Measuring Gear Radial Clearance

Using a dial indicator, measure the gear radial clearance.

Standard clearance

Bearing	Specified Condition
JTEKT made	0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made	0.009 to 0.051mm (0.0004 to 0.0020 in.)

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

REMOVE 4TH GEAR

Fig 5: Removing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
3. Using SST and a press, press out the input shaft rear bearing and 4th gear.
  
  Fig 6: Pressing Out Input Shaft Rear Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-00020
  NOTE:
  Do not overtighten the SST.
REMOVE 4TH GEAR NEEDLE ROLLER BEARING

Fig 7: Removing Needle Roller Bearing From Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the needle roller bearing from the input shaft.
REMOVE NO. 4 SYNCHRONIZER OUTER RING

Fig 8: Identifying 2nd Synchronizer Outer Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the No. 4 synchronizer outer ring from the No. 2 transaxle clutch hub.
REMOVE 4TH GEAR BUSH

Fig 9: Identifying 4th Gear Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 4th gear bush from the No. 2 transaxle clutch hub.
REMOVE 3RD GEAR

Fig 10: Removing No. 2 Clutch Hub Setting Shaft Snap Ring From Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
2. Using SST and a press, press out the No. 2 transaxle clutch hub and 3rd gear from the input shaft.
  
  Fig 11: Pressing No. 2 Transaxle Clutch Hub And 3rd Gear Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-00020
  NOTE:
  Do not overtighten the SST.
REMOVE 3RD GEAR NEEDLE ROLLER BEARING

Fig 12: Removing Needle Roller Bearing From Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the needle roller bearing from the input shaft.
REMOVE NO. 3 SYNCHRONIZER RING

Fig 13: Identifying No. 3 Synchronizer Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the No. 3 synchronizer ring from the 3rd gear.
REMOVE NO. 2 TRANSAXLE HUB SLEEVE

Fig 14: Removing No. 2 Transmission Hub Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
REMOVE INPUT SHAFT FRONT BEARING

Fig 15: Pressing Out Input Shaft Front Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press out the input shaft front bearing (inner race) from the input shaft.
  NOTE:
  Do not overtighten SST.