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Input Shaft: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT 6TH GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 6th gear thrust clearance.

      Standard clearance: 0.20 to 0.48 mm (0.0079 to 0.0189 in.) 

      If the clearance is outside the specification, replace the defective gear, thrust washer or shaft.

      Fig 1: Measuring 6th Gear Thrust Clearance Using Dial Indicator
      G04046557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT 3RD GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 3rd gear thrust clearance.

      Standard clearance: 0.19 to 0.51 mm (0.0075 to 0.0201 in.) 

      If the clearance is outside the specification, replace the defective gear, thrust washer, clutch hub or shaft.

      Fig 2: Measuring 3rd Gear Thrust Clearance Using Feeler Gauge
      G04046558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE 4TH GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 4th gear thrust clearance.

      Standard clearance: 0.12 to 0.38 mm (0.0047 to 0.0150 in.) 

      If the clearance is outside the specification, replace the defective gear, clutch hub or shaft.

      Fig 3: Measuring 4th Gear Thrust Clearance Using Dial Indicator
      G04046559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT 6TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 6th gear radial clearance.

      Standard clearance: 0.015 to 0.065 mm (0.0006 to 0.0026 in.) 

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

      Fig 4: Measuring 6th Gear Radial Clearance Using Dial Indicator
      G04046560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT 3RD GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear radial clearance.

      Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) 

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

      Fig 5: Measuring 3rd Gear Radial Clearance Using Dial Indicator
      G04046561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT 4TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 4th gear radial clearance.

      Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 in.) 

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

      Fig 6: Measuring 4th Gear Radial Clearance Using Dial Indicator
      G04046562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE NO. 3 TRANSMISSION CLUTCH HUB SHAFT SNAP RING 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      Use a shop rag or a piece of cloth to prevent the snap ring from flying off.

      Fig 7: Identifying No. 3 Transmission Clutch Hub Shaft Snap Ring
      G04046563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE 6TH GEAR 
    1. Using SST and a press, remove the No. 3 transmission clutch hub, hub sleeve, synchronizer ring and 6th gear from the input shaft.

      SST 09950-00020, 09950-70010 (09951-07200), 09950-60010 (09951-00300)

      Fig 8: Removing 6th Gear
      G04046564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not tighten SST excessively.
      • Support the input shaft by hand so that it does not fall off.
  9. REMOVE 6TH GEAR NEEDLE ROLLER BEARING 
    1. Remove the 6th gear needle roller bearing from the input shaft.
      Fig 9: Removing 6th Gear Needle Roller Bearing From Input Shaft
      G04046565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE SPACER 
    1. Remove the spacer from the input shaft.
      Fig 10: Removing Spacer From Input Shaft
      G04046566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE GEAR THRUST WASHER SHAFT SNAP RING 
    1. Using a snap ring expander, remove the snap ring from the input shaft.
      Fig 11: Removing Gear Thrust Washer Shaft Snap Ring
      G04046567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE 3RD GEAR THRUST WASHER 
    1. Remove the 3rd gear thrust washer from the input shaft.
      Fig 12: Removing 3rd Gear Thrust Washer From Input Shaft
      G04046568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE 3RD GEAR 
    1. Remove the 3rd gear from the input shaft.
      Fig 13: Removing 3rd Gear From Input Shaft
      G04046569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE STRAIGHT PIN 
    1. Remove the straight pin from the input shaft.
      Fig 14: Removing Straight Pin From Input Shaft
      G04046570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE 3RD GEAR NEEDLE ROLLER BEARING 
    1. Remove the 3rd gear needle roller bearing from the input shaft.
      Fig 15: Removing 3rd Gear Needle Roller Bearing From Input Shaft
      G04046571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE SPACER 
    1. Remove the spacer from the input shaft.
      Fig 16: Removing Spacer From Input Shaft
      G04046572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 2 SYNCHRONIZER RING SET 
    1. Remove the No. 2 synchronizer ring set from the input shaft.
      Fig 17: Removing No. 2 Synchronizer Ring Set From Input Shaft
      G04046573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING 
    1. Using a snap ring expander, remove the snap ring from the input shaft.
      Fig 18: Removing No. 2 Clutch Hub Setting Shaft Snap Ring
      G04046574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE 4TH GEAR 
    1. Using SST and a press, remove the No. 2 transmission clutch hub, hub sleeve, synchronizer ring and 4th gear from the input shaft.

      SST 09950-00020 

      NOTE: Support the input shaft by hand so that it does not fall off.
      Fig 19: Removing 4th Gear
      G04046575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE 4TH GEAR NEEDLE ROLLER BEARING 
    1. Remove the 4th gear needle roller bearing from the input shaft.
      Fig 20: Removing 4th Gear Needle Roller Bearing From Input Shaft
      G04046576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE INPUT SHAFT FRONT BEARING SNAP RING 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.
      Fig 21: Tapping Out Snap Ring
      G04046577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use a shop rag or a piece of cloth to prevent the snap ring from flying off.

  22. REMOVE INPUT SHAFT FRONT BEARING 
    1. Using SST and a press, remove the input shaft front bearing from the input shaft.

      SST 09950-00020 

      Fig 22: Identifying Input Shaft Front Bearing
      G04046578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Support the input shaft by hand so that it does not fall off.
  23. REMOVE NO. 2 TRANSMISSION CLUTCH HUB 
    1. Remove the clutch hub, 3 synchromesh shifting keys, 3 balls and 3 springs from the hub sleeve.
      Fig 23: Identifying No. 2 Transmission Clutch Hub
      G04046579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use a shop rag or a piece of cloth to prevent the ball and spring from flying off.

  24. REMOVE NO. 3 TRANSMISSION CLUTCH HUB 
    1. Perform the same procedures as for the No. 2 transmission clutch hub.
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