Input Shaft: Reassembly

HINT:

Before reassembly, coat all of the sliding and rotating surfaces with gear oil.

1. ASSEMBLE NO. 2 HUB SLEEVE AND NO. 2 CLUTCH HUB 
   1. Install the 3 No. 2 shifting key springs and 3 No. 2 shifting keys to the No. 2 clutch hub.
   2. Install the No. 2 hub sleeve to the No. 2 clutch hub.
   NOTE: Assemble the No. 2 hub sleeve and No. 2 clutch hub in the direction shown in the illustration.
   Fig 1: Installing No. 2 Hub Sleeve To No. 2 Clutch Hub

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, NO. 2 SYNCHRONIZER RING (FOR 3RD GEAR), NO. 2 HUB SLEEVE AND NO. 2 CLUTCH HUB ASSEMBLY 
   1. Apply gear oil to the needle roller bearing and install it.
   2. Install the 3rd gear and No. 2 synchronizer ring (for the 3rd gear).
      NOTE: Distinguish the No. 2 synchronizer ring (for the 3rd gear) by the teeth on the synchronizer ring.
      Fig 2: Installing 3Rd Gear And No. 2 Synchronizer Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Install the No. 2 hub sleeve and No. 2 clutch hub assembly so that the No. 2 synchronizer ring slots and No. 2 shifting keys are aligned.
      NOTE: Be sure to install the No. 2 hub sleeve and No. 2 clutch hub assembly in the correct direction, as shown in the illustration.
   4. Using a press, press in the No. 2 hub sleeve and No. 2 clutch hub assembly.
   Fig 3: Pressing No. 2 Hub Sleeve And No. 2 Clutch Hub Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL SNAP RING 
   1. Select a snap ring from the table below that will make the thrust clearance of the No. 2 clutch hub less than 0.1 mm (0.004 in.).
      Fig 4: Thickness Specification Chart

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a screwdriver and hammer, tap in the snap ring.
   NOTE: Take care not to damage the journal surface of the input shaft.
4. INSPECT 3RD GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
   Fig 5: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL SPACER, NEEDLE ROLLER BEARING, No. 2 SYNCHRONIZER RING (FOR 4TH GEAR), 4TH GEAR AND REAR RADIAL BALL BEARING 
   1. Install the spacer.
   2. Apply gear oil to the needle roller bearings and install it.
   3. Place the No. 2 synchronizer ring (for the 4th gear) on the No. 2 hub sleeve assembly and align the No. 2 synchronizer ring slots with the No. 2 shifting keys.
   4. Install the 4th gear.
      NOTE: Distinguish the No. 2 synchronizer ring (for the 4th gear) by the teeth on the synchronizer ring.
      Fig 6: Installing 4Th Gear

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Using SST and a press, press in the rear radial ball bearing.

      SST 09608-00071

   NOTE: Be sure to install the rear radial ball bearing in the correct direction, as shown in the illustration.

   HINT:

   Set SST to the bearing inner race securely.

   Fig 7: Pressing Rear Radial Ball Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL SNAP RING 
   1. Select a snap ring from the table below that will make the thrust clearance of the rear radial ball bearing less than 0.1 mm (0.0039 in.).
      Fig 8: Thickness Specification Chart

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a screwdriver and hammer, tap in the snap ring.
   NOTE: Take care not to damage the journal surface of the input shaft.
7. INSPECT 4TH GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
   Fig 9: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002