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Input Shaft: Reassembly

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL INPUT SHAFT FRONT BEARING 
    1. Using SST and a press, install the input shaft front bearing (inner race).

      SST 09608-00071 

      Fig 1: Installing Input Shaft Front Bearing (Inner Race)
      G04977411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 2 TRANSMISSION HUB SLEEVE 
    1. Coat the No. 2 transmission hub sleeve with gear oil.
    2. Install the 3 synchromesh key springs with the No. 2 transmission hub sleeve.
      NOTE: Install the No. 2 transmission clutch hub sleeve and the No. 2 transmission clutch hub in the correct direction.
    3. Using a screwdriver, install the synchromesh shifting key to the input shaft.
      Fig 2: Installing Synchromesh Shifting Key To Input Shaft
      G06013302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL 3RD GEAR NEEDLE ROLLER BEARING 
    1. Coat the 3rd gear bearing with gear oil and install it to the input shaft.
      Fig 3: Identifying 3rd Gear Bearing
      G04977393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL 3RD GEAR 
    1. Coat the 3rd gear with gear oil and install it to the input shaft.
      Fig 4: Identifying 3rd Gear
      G04977414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 3 SYNCHRONIZER RING 
    1. Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear.
      Fig 5: Installing No. 3 Synchronizer Ring
      G04977415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 2 TRANSMISSION CLUTCH HUB 
    1. Using SST and a press, install the No. 2 transmission clutch hub to the input shaft.

      SST 09316-60011 (09316-00041) 

      NOTE:
      • Align the claw of the No. 2 clutch hub with the notch of the No. 3 synchronizer ring.
      • Make sure that the 3rd gear can rotate.
        Fig 6: Installing No. 2 Transmission Clutch Hub To Input Shaft
        G04977416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring so that clearance between the No. 2 transmission clutch hub and the No. 2 clutch hub shaft snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring.

      Standard clearance: 

      0.1 mm (0.00394 in.) or less 

      Snap Ring Thickness 

      Fig 7: Installing Snap Ring
      G04977417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING REFERENCE CHART

      Part No. Thickness: mm (in.) Mark
      90520-34003 2.30 to 2.35 (0.0906 to 0.0925) H
      90520-34004 2.35 to 2.40 (0.0925 to 0.0945) J
      90520-34005 2.40 to 2.45 (0.0945 to 0.0965) K
      90520-34006 2.45 to 2.50 (0.0965 to 0.0984) L
      90520-34007 2.50 to 2.55 (0.0984 to 0.1004) M
      90520-34008 2.55 to 2.60 (0.1004 to 0.1024) N
      90520-34009 2.60 to 2.65 (0.1024 to 0.1043) P
  7. INSTALL 4TH GEAR BEARING SPACER 
    1. Coat the 4th gear bearing spacer with gear oil and install it to the input shaft.
      Fig 8: Identifying 4th Gear Bearing Spacer
      G04977390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 4 SYNCHRONIZER RING 
    1. Coat the No. 4 synchronizer ring with gear oil and install it to the No. 2 transmission clutch hub.
      NOTE: Align the claw of the No. 2 clutch hub with the notch of the No. 4 synchronizer ring.
      Fig 9: Identifying No. 4 Synchronizer Ring
      G04977389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL 4TH GEAR NEEDLE ROLLER BEARING 
    1. Coat the 4th gear needle roller bearing with gear oil and install it to the input shaft.
      Fig 10: Identifying 4th Gear Needle Roller Bearing
      G04977388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL 4TH GEAR 
    1. Coat the 4th gear with gear oil and install it to the input shaft.
      Fig 11: Identifying 4th Gear
      G04977421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. 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 09608-06041 

      NOTE:
      • Install the bearing with its groove facing rearward.
      • Make sure that the 3rd gear can rotate.
        Fig 12: Installing Input Shaft Rear Radial Ball Bearing To Input Shaft
        G04977422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring so that the clearance between the input shaft radial ball rear bearing and the input shaft rear bearing snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring.

      Standard Clearance: 

      0.1 mm (0.00394 in.) or less 

      Fig 13: Installing Snap Ring
      G04977423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Snap Ring 

      SNAP RING REFERENCE CHART

      Part No. Thickness: mm (in.) Mark
      90520-30008 2.35 to 2.40 (0.0925 to 0.0945) 1
      90520-30009 2.40 to 2.45 (0.0945 to 0.0965) 2
      90520-30010 2.45 to 2.50 (0.0965 to 0.0984) 3
      90520-30011 2.50 to 2.55 (0.0984 to 0.1004) 4
      90520-30012 2.55 to 2.60 (0.1004 to 0.1024) 5
      90520-30013 2.60 to 2.65 (0.1024 to 0.1043) 6
      90520-30021 2.65 to 2.70 (0.1043 to 0.1063) 7
      90520-30022 2.70 to 2.75 (0.1063 to 0.1083) 8
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