Input Shaft: Disassembly

INSPECT 3RD AND 4TH GEARS THRUST CLEARANCE

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

3RD AND 4TH GEAR - STANDARD CLEARANCE TABLE

3rd gear	0.10 to 0.35 mm (0.0039 to 0.0138 in.)
4th gear	0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

3RD AND 4TH GEAR - MAXIMUM CLEARANCE TABLE

3rd gear	0.35 mm (0.0138 in.)
4th gear	0.55 mm (0.0217 in.)

Fig 1: Measuring Thrust Clearance Using A Feeler Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 3RD AND 4TH GEARS RADIAL CLEARANCE

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

Standard clearance:

3RD AND 4TH GEAR - STANDARD CLEARANCE TABLE

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:

3RD AND 4TH GEAR - MAXIMUM CLEARANCE TABLE

KOYO made	0.058 mm (0.0023 in.)
NSK made	0.056 mm (0.022 in.)

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

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

HINT:

Take care not to damage the journal surface of the input shaft.

Fig 2: Measuring Radial Clearance Between Gear And Shaft Using A Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR RADIAL BALL BEARING, 4TH GEAR, NEEDLE ROLLER BEARING, SPACER AND NO. 2 SYNCHRONIZER RING (FOR 4TH GEAR)
1. Using SST and a press, press out the rear radial ball bearing and 4th gear.
  SST 09950-00020
  
  HINT:
  
  Support the input shaft assembly by hand so that it will not be dropped off.
  
  Fig 3: Removing Rear Radial Ball Bearing And 4Th Gear Using SST And A Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the needle roller bearing, spacer and No. 2 synchronizer ring (for the 4th gear).
REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT:

Take care not to damage the journal surface of the input shaft.

Fig 4: Identifying SST Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 HUB SLEEVE, NO. 2 CLUTCH HUB ASSEMBLY, NO. 2 SYNCHRONIZER RING (FOR 3RD GEAR), 3RD GEAR AND NEEDLE ROLLER BEARING
1. Using SST and a press, press out the No. 2 hub sleeve, No. 2 clutch hub assembly, No. 2 synchronizer ring (for the 3rd gear) and 3rd gear.
  SST 09950-00020
  
  HINT:
  
  Support the input shaft by hand so that it will not be dropped off.
2. Remove the needle roller bearing.
DISASSEMBLE NO. 2 HUB SLEEVE AND NO. 2 CLUTCH HUB
1. Remove the No. 2 hub sleeve from the No. 2 clutch hub.
2. Remove the 3 No. 2 shifting keys and 3 No. 2 shifting key springs from the No. 2 clutch hub.
Fig 5: Removing No. 2 Hub Sleeve From No. 2 Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002