Input Shaft: Reassembly

INSTALL NO. 2 TRANSMISSION HUB SLEEVE
1. Coat the No. 2 transmission hub sleeve with gear oil.
2. Install the 3 synchromesh shifting key springs and 3 synchromesh shifting keys to the No. 2 transmission clutch hub.
  
  Fig 1: Identifying Synchromesh Shifting Key Springs And Synchromesh Shifting Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the No. 2 transmission clutch hub onto the No. 2 transmission hub sleeve.
  NOTE: Position the No. 2 transmission hub sleeve and No. 2 transmission clutch hub correctly as shown in the illustration.
  
  Fig 2: Identifying No. 2 Transmission Clutch Hub And No. 2 Transmission Hub Sleeve
  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 3: Identifying 3Rd Gear Needle Roller Bearing
  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 4: Installing 3rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD GEAR SYNCHRONIZER RING
1. Coat the 3rd gear synchronizer ring with gear oil and install it onto the 3rd gear.
  
  Fig 5: Installing 3Rd Gear Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 2 TRANSMISSION CLUTCH HUB

Using SST and a press, install the No. 2 transmission clutch hub onto the input shaft.
SST 09316-60011 (09316-00021)

NOTE: Fit the synchromesh shifting keys into the grooves of the synchronizer ring correctly.

Fig 6: Installing No. 2 Transmission Clutch Hub Onto Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring that will allow minimum axial play.

Standard clearance:

0.1 mm (0.00394 in.) or less

Snap Ring Thickness

SNAP RING THICKNESS REFERENCE CHART

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
0	2.30 (0.0906)	3	2.48 (0.0976)
1	2.36 (0.0929)	4	2.54 (0.1000)
2	2.42 (0.0953)	5	2.60 (0.1024)

Fig 7: Selecting Snap Ring That Will Allow Minimum Axial Play

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSTALL 4TH GEAR SYNCHRONIZER RING
1. Coat the 4th gear synchronizer ring with gear oil and install it onto the No. 2 transmission clutch hub.
  
  Fig 8: Installing 4Th Gear Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH GEAR NEEDLE ROLLER BEARING
1. Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install them onto the No. 2 transmission clutch hub.
  
  Fig 9: Identifying 4Th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH GEAR
1. Coat the 4th gear with gear oil and install it onto the input shaft.
  
  Fig 10: Identifying 4Th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SHAFT REAR RADIAL BALL BEARING

Using SST and a press, install the input shaft rear radial ball bearing onto the input shaft.
SST 09608-04031

Fig 11: Installing Input Shaft Rear Radial Ball Bearing Onto Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring that will allow minimum axial play.

Standard clearance:

0.1 mm (0.00394 in.) or less

Snap Ring Thickness

SNAP RING THICKNESS REFERENCE CHART

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.29 (0.0901)	D	2.47 (0.0972)
B	2.35 (0.0925)	E	2.53 (0.0996)
C	2.41 (0.0948)	F	2.59 (0.1019)

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

Fig 12: Selecting Snap Ring That Will Allow Minimum Axial Play
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Do not damage the snap ring journal surface.

INSPECT 3RD GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 3rd gear radial clearance.
  Standard clearance:
  
  NSK made bearing:
  
  0.015 to 0.056 mm (0.000591 to 0.00220 in.)
  
  KOYO made bearing:
  
  0.015 to 0.058 mm (0.000591 to 0.00228 in.)
  
  Maximum clearance:
  
  NSK made bearing:
  
  0.056 mm (0.00220 in.)
  
  KOYO made bearing:
  
  0.058 mm (0.00228 in.)
  
  Fig 13: Measuring 3Rd Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.
INSPECT 4TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.
  Standard clearance:
  
  NSK made bearing:
  
  0.009 to 0.050 mm (0.000354 to 0.00197 in.)
  
  KOYO made bearing:
  
  0.009 to 0.050 mm (0.000354 to 0.00197 in.)
  
  Maximum clearance:
  
  NSK made bearing:
  
  0.050 mm (0.00197 in.)
  
  KOYO made bearing:
  
  0.050 mm (0.00197 in.)
  
  Fig 14: Measuring 4Th Gear Radial Clearance Between Gear And Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.
INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 3rd gear thrust clearance.
  Standard clearance:
  
  0.10 to 0.35 mm (0.00394 to 0.0138 in.)
  
  Maximum clearance:
  
  0.35 mm (0.0138 in.)
  
  If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.
  
  Fig 15: Measuring 3Rd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 4TH GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 4th gear thrust clearance.
  Standard clearance:
  
  0.10 to 0.55 mm (0.00394 to 0.0217 in.)
  
  Maximum clearance:
  
  0.55 mm (0.0217 in.)
  
  If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.
  
  Fig 16: Measuring 4Th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002