Input Shaft: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSTALL INPUT SHAFT FRONT BEARING
1. Using SST and a press, install the input shaft front bearing onto the input shaft.
  SST 09950-00020
  
  Fig 1: Installing Input Shaft Front Bearing Onto Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Make sure that the groove of the bearing faces the correct direction.

INSTALL INPUT SHAFT FRONT BEARING SNAP RING

Select a snap ring that will allow minimum axial play.

Standard clearance: 0.1 mm (0.004 in.) or less

Snap ring thickness

INPUT SHAFT FRONT BEARING SNAP RING

Part No.	Thickness: mm (in.)	Mark
90520-31026	2.65 to 2.70 (0.1043 to 0.1063)	A
90520-31027	2.70 to 2.75 (0.1063 to 0.1083)	B
90520-31028	2.75 to 2.80 (0.1083 to 0.1102)	C
90520-31029	2.80 to 2.85 (0.1102 to 0.1122)	D
90520-31030	2.85 to 2.90 (0.1122 to 0.1142)	E
90520-31031	2.90 to 2.95 (0.1142 to 0.1161)	F

Fig 2: Identifying Input Shaft Front Bearing Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSTALL NO. 2 TRANSMISSION CLUTCH HUB
1. Apply a light coat of gear oil to the sleeve and hub.
2. Install the clutch hub sleeve onto the No. 2 transmission clutch hub.
3. Install the 3 shifting keys, 3 shifting key springs and 3 balls onto the clutch hub.
  NOTE: Take care to prevent the ball from flying off.
  
  Fig 3: Identifying No. 2 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Make sure that the No. 2 transmission clutch hub faces the correct direction.
INSTALL NO. 3 TRANSMISSION CLUTCH HUB
1. Apply a light coat of gear oil to the sleeve and hub.
2. Install the clutch hub sleeve onto the No. 3 transmission clutch hub.
3. Install the 3 shifting keys, 3 shifting key springs and 3 balls onto the clutch hub.
  NOTE: Take care to prevent the ball from flying off.
  
  Fig 4: Identifying No. 3 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Make sure that the No. 2 transmission clutch hub faces the correct direction.
INSTALL 4TH GEAR NEEDLE ROLLER BEARING
1. Coat the 4th gear needle roller bearing with gear oil, then install it onto the input shaft.
Fig 5: Identifying 4th Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH GEAR
1. Coat the 4th gear and No. 3 synchronizer ring with gear oil, then install them onto the input shaft.
2. Using SST and a press, install the No. 2 transmission clutch hub onto the input shaft.
  SST 09308-14010
  
  HINT:
  
  Align the convex portion of the synchronizer ring with the groove of the clutch hub.
  
  Fig 6: Installiang No. 2 Transmission Clutch Hub Onto Input Shaft Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.

INSTALL NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

Select a snap ring that will allow minimum axial play.

Standard clearance: 0.1 mm (0.004 in.) or less

Snap ring thickness

Fig 7: Installing No. 2 Clutch Hub Setting Shaft Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

Part No.	Thickness: mm (in.)	Mark
90520-42012	1.80 to 1.85 (0.0709 to 0.0728)	A
90520-42013	1.85 to 1.90 (0.0728 to 0.0748)	B
90520-42014	1.90 to 1.95 (0.0748 to 0.0768)	C
90520-42015	1.95 to 2.00 (0.0768 to 0.0787)	D
90520-42016	2.00 to 2.05 (0.0787 to 0.0807)	E
90520-42017	2.05 to 2.10 (0.0807 to 0.0827)	F
90520-42018	2.10 to 2.15 (0.0827 to 0.0846)	G

Using a snap ring expander, install the snap ring onto the input shaft.

INSTALL NO. 2 SYNCHRONIZER RING SET
1. Coat the No. 2 synchronizer ring set with gear oil, then install it onto the input shaft.
  
  Fig 8: Identifying No. 2 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPACER
1. Coat the spacer with gear oil, and install it onto the input shaft.
  
  Fig 9: Identifying Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 10: Identifying 3rd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STRAIGHT PIN
1. Install the straight pin onto the input shaft.
  
  Fig 11: Installing Straight Pin Onto Input Shaft
  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 12: Identifying 3rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD GEAR THRUST WASHER
1. Coat the 3rd gear thrust washer with gear oil, and install it onto the input shaft.
  
  Fig 13: Identifying 3rd Gear Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Align the straight pin with the groove of the gear thrust washer and install it.

INSTALL GEAR THRUST WASHER SHAFT SNAP RING

Select a snap ring that will allow minimum axial play.

Standard clearance: 0.1 mm (0.004 in.) or less Snap ring thickness

GEAR THRUST WASHER SHAFT SNAP RING

Part No.	Thickness: mm (in.)	Mark
90520-39026	2.07 to 2.12 (0.0815 to 0.0835)	A
90520-39027	2.12 to 2.17 (0.0835 to 0.0854)	B
90520-39028	2.17 to 2.22 (0.0854 to 0.0874)	C
90520-39029	2.22 to 2.27 (0.0874 to 0.0894)	D
90520-39030	2.27 to 2.32 (0.0894 to 0.0913)	E
90520-39031	2.32 to 2.37 (0.0913 to 0.0933)	F

Fig 14: Identifying Gear Thrust Washer Shaft Snap Ring

Using a snap ring expander, install the snap ring onto the input shaft.

INSTALL SPACER
1. Coat the spacer with gear oil, and install it onto the input shaft.
  
  Fig 15: Identifying Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 6TH GEAR NEEDLE ROLLER BEARING
1. Coat the 6th gear needle roller bearing with gear oil, and install it onto the input shaft.
  
  Fig 16: Identifying 6th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 6TH GEAR
1. Install the 6th gear onto the input shaft.
2. Install the synchronizer ring onto the input shaft.
3. Using SST and a press, install the clutch hub onto the input shaft.
  SST 09309-37010, 09950-00020
4. Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.
  
  Fig 17: Installing 6th Gear Onto Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION CLUTCH HUB NO. 3 SHAFT SNAP RING

Select a snap ring that will allow minimum axial play.

Standard clearance: 0.1 mm (0.004 in.) or less

Snap ring thickness

Fig 18: Identifying Transmission Clutch Hub No. 3 Shaft Snap Ring

TRANSMISSION CLUTCH HUB NO. 3 SHAFT SNAP RING

Part No.	Thickness: mm (in.)	Mark
90520-33022	2.10 to 2.15 (0.0827 to 0.0847)	A
90520-33023	2.15 to 2.20 (0.0847 to 0.0866)	B
90520-33024	2.20 to 2.25 (0.0866 to 0.0886)	C
90520-33025	2.25 to 2.30 (0.0886 to 0.0906)	D
90520-33026	2.30 to 2.35 (0.0906 to 0.0925)	E
90520-33027	2.35 to 2.40 (0.0925 to 0.0945)	F
90520-33028	2.40 to 2.45 (0.0945 to 0.0965)	G

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

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 19: Measuring 6th Gear Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 20: Measuring 3rd Gear Thrust Clearance Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 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 21: Measuring 4th Gear Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 22: Measuring 6th Gear Radial Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 23: Measuring 3rd Gear Radial Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 24: Measuring 4th Gear Radial Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002