Input Shaft: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL INPUT SHAFT FRONT BEARING INNER RACE 

   Using SST and a press, install a new input shaft front bearing inner race.

   SST 09608-00071

   Fig 1: Installing Input Shaft Front Bearing Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL NO. 2 CLUTCH HUB INTO NO. 2 HUB SLEEVE 
   1. Install the 3 springs and shifting keys to the clutch hub.
   2. Install the hub sleeve to the clutch hub.
      NOTE: Assembly the hub sleeve and clutch hub in the direction shown in Fig 2.
      Fig 2: Installing Springs And Shifting Keys To Clutch Hub

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, SYNCHRONIZER RING AND NO. 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT 
   1. Apply MP grease to the needle roller bearing and install it.
   2. Install the 3rd gear.
   3. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
   4. Using SST and a press, install the No. 2 hub sleeve assembly.

      SST 09506-35010

      Fig 3: Installing No. 2 Hub Sleeve Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL SNAP RING 
   1. Select a snap ring that allows the minimum axial play.
      Fig 4: Selecting Snap Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS SPECIFICATION CHART
      
      

      Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
      H	2.30 (0.0906)	M	2.50 (0.0984)
      J	2.35 (0.0925)	N	2.55 (0.1004)
      K	2.40 (0.0945)	P	2.60 (0.1024)
      L	2.45 (0.0965)	-	-

   2. Using a screwdriver and hammer, tap in the snap ring.
5. MEASURE 3RD GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
6. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, 4TH GEAR AND REAR BEARING 
   1. Install the spacer.
   2. Apply MP grease to the 2 needle roller bearings and install it.
   3. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
   4. Install the 4th gear.
   5. Using SST and a press, install the rear bearing.

      SST 09309-36010

      Fig 5: Installing Rear Bearing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL SNAP RING 
   1. Select a snap ring that allows the minimum axial play.
      Fig 6: Selecting Snap Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS SPECIFICATION CHART
      
      

      Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
      1	2.35 (0.0925)	5	2.55 (0.1004)
      2	2.40 (0.0945)	6	2.60 (0.1024)
      3	2.45 (0.0965)	7	2.65 (0.1043)
      4	2.50 (0.0984)	8	2.70 (0.1063)

   2. Using a screwdriver and hammer, tap in the snap ring.
8. MEASURE 4TH GEAR THRUST CLEARANCE (See  DISASSEMBLY  )