Input Shaft: Disassembly

Using a feeler gauge, measure the thrust clearance.

Standard clearance: 

3rd gear: 0.10 - 0.35 mm (0.0039 - 0.0138 in.) 

4th gear: 0.10 - 0.55 mm (0.0039 - 0.0217 in.) 

Maximum clearance: 

3rd gear: 0.35 mm (0.0138 in.) 

4th gear: 0.55 mm (0.0217 in.) 

Fig 1: Measuring Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a dial indicator, measure the radial clearance between the gear and shaft.

Standard clearance: 

KOYO made: 

0.015 - 0.058 mm (0.0006 - 0.0023 in.) 

NSK made: 

0.015 - 0.056 mm (0.0006 - 0.0022 in.) 

Maximum clearance: 

KOYO made: 0.058 mm (0.0023 in.) 

NSK made: 0.056 mm (0.0022 in.) 

Fig 2: Measuring Radial Clearance Between Gear And Shaft

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.

Using 2 screwdrivers and a hammer, tap out the snap ring.

1. Using SST and a press, remove the rear ball bearing and 4th gear.

   SST 09950-00020

2. Remove the needle roller bearings, spacer and synchronizer ring.

Using 2 screwdrivers and a hammer, tap out the snap ring.

Fig 3: Removing Rear Ball Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, remove the No. 2 hub sleeve assembly, 3rd gear and synchronizer ring.

   SST 09950-00020

2. Remove the needle roller bearings.
   Fig 4: Removing Needle Roller Bearings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the 2 shifting key springs and 3 shifting keys from the No. 2 clutch hub.
2. Remove the No. 2 hub sleeve from the No. 2 clutch hub.
   Fig 5: Removing No. 2 Hub Sleeve From No. 2 Clutch Hub

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002