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Input Shaft ASSY (C59): Overhaul

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT 4TH GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 4th gear thrust clearance.
    Fig 1: 4th Gear Thrust Clearance Specifications
    G00922000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    4th gear thrust clearance: 

    Fig 2: Measuring 4th Gear Thrust Clearance
    G00922001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT 3RD GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear thrust clearance.
    Fig 3: 3rd Gear Thrust Clearance Specifications
    G00922002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    3rd gear thrust clearance: 

    Fig 4: Measuring 3rd Gear Thrust Clearance
    G00922003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT 4TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 4th gear radial clearance.
    Fig 5: 4th Gear Radial Clearance Specifications
    G00922004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    4th gear radial clearance: 

    Fig 6: Measuring 4th Gear Radial Clearance
    G00922005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  4. INSPECT 3RD GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear radial clearance.
    Fig 7: 3rd Gear Radial Clearance Specifications
    G00922006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    3rd gear radial clearance: 

    Fig 8: Measuring 3rd Gear Radial Clearance
    G00922007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  5. REMOVE 4TH GEAR 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.
      NOTE:

      Using a waste to prevent the snap ring from being scattered.

      Fig 9: Removing Snap Ring
      G00922008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the input shaft radial ball bearing rear and 4th gear from the input shaft.

      SST 09950-00020

    NOTE:
    • Do not tighten SST excessively.
    • Support the input shaft assy by hand so that it will not be dropped off.
    Fig 10: Removing 4th Gear
    G00922009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING 
    1. Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.
    Fig 11: Removing 4th Gear Needle Roller Bearing
    G00922010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE 4TH GEAR SYNCHRONIZER RING 
    1. Remove the 4th gear synchronizer ring from the transmission clutch hub No. 2.
    Fig 12: Removing 4th Gear Synchronizer Ring
    G00922011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE 3RD GEAR 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.
      NOTE:

      Using a waste to prevent the snap ring from being scattered.

      Fig 13: Removing Snap Ring
      G00922012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the transmission clutch hub No. 2 and 3rd gear from the input shaft.

      SST 09950-00020

    NOTE:
    • Do not tighten SST excessively.
    • Support the input shaft by hand so that it will not be dropped off.
    Fig 14: Removing 3rd Gear
    G00922013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE 3RD GEAR SYNCHRONIZER RING 
    1. Remove the 3rd gear synchronizer ring from the 3rd gear.
    Fig 15: Removing 3rd Gear Synchronizer Ring
    G00922014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING 
    1. Remove the 3rd gear needle roller bearing from the input shaft.
    Fig 16: Removing 3rd Gear Needle Roller Bearing
    G00922015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSMISSION HUB SLEEVE NO. 2 
    1. Remove the transmission hub sleeve No. 2, 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the transmission clutch hub No. 2.
    NOTE:

    Using a waste to prevent the shifting key and shifting key spring from being scattered.

    Fig 17: Removing Transmission Hub Sleeve No. 2
    G00922016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT INPUT SHAFT 
    1. Using a dial indicator, check the shaft runout.
      1. Maximum runout: 0.015 mm (0.006 in.) 

      If the runout exceeds the maximum, replace the input shaft.

      Fig 18: Checking Input Shaft Runout
      G00922017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a micrometer, measure the outer diameter of the input shaft journal surface.

    Input shaft outer diameter: 

    Fig 19: Input Shaft Outer Diameter Specifications
    G00922018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the outer diameter is below the minimum, replace the input shaft.

    Fig 20: Measuring Outer Diameter Of Input Shaft Journal Surface
    G00922019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT 4TH GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
      1. Standard inside diameter: 34.015 - 34.031 mm (1.3391 - 1.3398 in.) 
      2. Maximum inside diameter: 34.031 mm (1.3398 in.) 

    If the inside diameter exceeds the maximum, replace the 4th gear.

    Fig 21: Measuring Inside Diameter Of 4th Gear
    G00922020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT 3RD GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.
      1. Standard inside diameter: 36.015 - 36.031 mm (1.4179 - 1.4185 in.) 
      2. Maximum inside diameter: 36.031 mm (1.4185 in.) 

    If the inside diameter exceeds the maximum, replace the 3rd gear.

    Fig 22: Measuring Inside Diameter Of 3rd Gear
    G00922021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT 4TH GEAR SYNCHRONIZER RING 
    1. Check for wear or damage.
    2. Check the braking effect of the 3rd gear synchronizer ring. Turn the 3rd gear synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.

      If the braking effect is insufficient, apply a small amount of the fine lapping compound between 3rd gear synchronizer ring and 3rd gear cone. Lightly rub the 3rd gear synchronizer ring and 3rd gear cone together.

      Fig 23: Inspecting 4th Gear Synchronizer Ring
      G00922022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
    3. Check again the braking effect of the synchronizer ring.
    4. Using a feeler gauge, measure the clearance between 3rd gear synchronizer ring back and 3rd gear spline end.
      1. Minimum clearance: 0.65 mm (0.0256 in.) 

    If the clearance below than the minimum, replace the 3rd gear synchronizer ring, and apply small amount of the fine lapping compound on gear cone.

    Fig 24: Measuring Clearance Between 3rd Gear Synchronizer Ring Back And 3rd Gear Spline End
    G00922023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
  16. INSPECT 3RD GEAR SYNCHRONIZER RING 
    1. Check for wear or damage.
    2. Check the braking effect of the 4th gear synchronizer ring. Turn the 4th gear synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.

      If the braking effect is insufficient, apply a small amount of the fine lapping compound between 4th gear synchronizer ring and 4th gear cone. Lightly rub the 4th gear synchronizer ring and 4th gear cone.

      Fig 25: Inspecting 3rd Gear Synchronizer Ring
      G00922024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
    3. Using a feeler gauge, measure the clearance between 4th gear synchronizer ring back and 4th gear spline end.
      1. Minimum clearance: 0.75 mm (0.0295 in.) 

    If the clearance below than the minimum, replace the 4th gear synchronizer ring, and apply small amount of the fine lapping compound on gear cone.

    NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
    Fig 26: Measuring Clearance Between 4th Gear Synchronizer Ring Back And 4th Gear Spline End
    G00922025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT TRANSMISSION HUB SLEEVE NO. 2 
    1. Check the sliding condition between the transmission hub sleeve No. 2 and transmission clutch hub No. 2.
    2. Check that the spline gear's edges of the transmission hub sleeve No. 2 is not worn down.
      Fig 27: Inspecting Transmission Hub Sleeve No. 2
      G00922026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a vernier caliper, inspect the transmission hub sleeve No. 2 and gear shift fork No. 2 as shown in Fig 28 .
      1. Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0137 in.) 

    If the clearance is out of specification, replace the transmission hub sleeve No. 2 and gear shift fork No. 2.

    Fig 28: Inspecting Transmission Hub Sleeve No. 2 And Gear Shift Fork No. 2
    G00922027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL TRANSMISSION HUB SLEEVE NO. 2 
    1. Coat the transmission hub sleeve No. 2 with gear oil, install it to the transmission clutch hub No. 2.
      Fig 29: Installing Transmission Hub Sleeve No. 2
      G00922028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not set the transmission clutch hub sleeve No. 2 and the transmission clutch hub No. 2 in incorrect orientation.
    2. Install the 2 synchromesh key springs with 3 synchromesh shifting keys to the transmission clutch hub No. 2.
    NOTE:

    Do not set the both openings of the shifting key springs in the same position.

  19. INSTALL 3RD GEAR NEEDLE ROLLER BEARING 
    1. Coat the 3rd gear needle roller bearing with gear oil, install it to the input shaft.
    Fig 30: Installing 3rd Gear Needle Roller Bearing
    G00922029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL 3RD GEAR 
    1. Coat the 3rd gear with gear oil, install it to the input shaft.
    Fig 31: Installing 3rd Gear
    G00922030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL 3RD GEAR SYNCHRONIZER RING 
    1. Coat the 3rd gear synchronizer ring with gear oil, install it to the 3rd gear.
    Fig 32: Installing 3rd Gear Synchronizer Ring
    G00922031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL TRANSMISSION CLUTCH HUB NO. 2 
    1. Using SST and a press, install the transmission clutch hub No. 2 to the input shaft.

      SST 09316-60011 (09316-00021)

      Fig 33: Installing Transmission Clutch Hub No. 2
      G00922032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 2 below 0.1 mm (0.004 in.).

      Snap ring thickness: 

      Fig 34: Snap Ring Thickness Specifications
      G00922033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, tap in the snap ring.
    NOTE: Take care not to damage the journal surface of the input shaft.
    Fig 35: Tapping Snap Ring
    G00922034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL 4TH GEAR SYNCHRONIZER RING 
    1. Coat the 4th gear synchronizer ring with gear oil, install it to the transmission clutch hub No. 2.
    Fig 36: Installing 4th Gear Synchronizer Ring
    G00922035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL 4TH GEAR NEEDLE ROLLER BEARING 
    1. Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil, install them to the input shaft.
    Fig 37: Installing 4th Gear Needle Roller Bearing
    G00922036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL 4TH GEAR 
    1. Coat the 4th gear with gear oil, install it to the input shaft.
    Fig 38: Installing 4th Gear
    G00922037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, install the input shaft rear radial ball bearing to the input shaft.

      SST 09636-20010

      Fig 39: Installing Input Shaft Rear Radial Ball Bearing
      G00922038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring from the table below that will make the thrust clearance of the input shaft rear radial ball bearing below 0.1 mm (0.004 in.).
      Fig 40: Snap Ring Thickness Specifications
      G00922039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Snap ring thickness: 

      Fig 41: Tapping Snap Ring
      G00922040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, tap in the snap ring.
    NOTE: Take care not to damage the journal surface of the snap ring.
  27. INSPECT 3RD GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear radial clearance.
    Fig 42: 3rd Gear Radial Clearance Specifications
    G00922041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    3rd gear radial clearance: 

    Fig 43: Measuring 3rd Gear Radial Clearance
    G00922042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  28. INSPECT 4TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 4th gear radial clearance.
    Fig 44: 4th Gear Radial Clearance Specifications
    G00922043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    4th gear radial clearance: 

    Fig 45: Measuring 4th Gear Radial Clearance
    G00922044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  29. INSPECT 3RD GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear thrust clearance.
    Fig 46: 3rd Gear Thrust Clearance Specifications
    G00922045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    3rd gear thrust clearance: 

    Fig 47: Measuring 3rd Gear Thrust Clearance
    G00922046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSPECT 4TH GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 4th gear thrust clearance.
    Fig 48: 4th Gear Thrust Clearance Specifications
    G00922047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    4th gear thrust clearance: 

    Fig 49: Measuring 4th Gear Thrust Clearance
    G00922048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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