Input Shaft: Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

INSPECT 4TH GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 4th gear thrust clearance.
  
  Fig 1: Measuring 4th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 3rd gear thrust clearance.
  
  Fig 2: Measuring 3rd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT 4TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.
  
  Fig 3: Measuring 4th Gear Radial Clearance Between Gear And Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.)
  
  If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.
INSPECT 3RD GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 3rd gear radial clearance.
  
  Fig 4: Measuring 3rd Gear Radial Clearance Between Gear & Shaft Using Dial Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.)
  
  If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.
REMOVE 4TH GEAR
1. Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.
  
  Fig 5: Removing Input Shaft Rear Bearing Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Use a piece of cloth to keep the snap ring from flying off.
2. Using SST and a press, remove the input shaft rear radial ball bearing and 4th gear from the input shaft.
  
  Fig 6: Identifying SST, Press, Input Shaft Rear Radial Ball Bearing & 4th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-00020
  HINT:
  - Do not tighten SST excessively.
  - Support the input shaft assembly by hand to prevent it from dropping off.
REMOVE 4TH GEAR NEEDLE ROLLER BEARING
1. Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.
  
  Fig 7: Identifying 4th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR SYNCHRONIZER RING
1. Remove the 4th gear synchronizer ring from the No. 2 transmission clutch hub.
  
  Fig 8: Identifying 4th Gear Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR
1. Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.
  
  Fig 9: Removing Clutch Hub No. 2 Setting Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Use a piece of cloth to keep the snap ring from flying off.
2. Using SST and a press, remove the No. 2 transmission clutch hub and 3rd gear from the input shaft.
  
  Fig 10: Identifying SST, Press, Transmission Clutch Hub No. 2 & 3rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-00020
  NOTE:
  - Do not tighten SST excessively.
  - Support the input shaft by hand to prevent it from dropping off.
REMOVE 3RD GEAR SYNCHRONIZER RING
1. Remove the 3rd gear synchronizer ring from the 3rd gear.
  
  Fig 11: Identifying Synchronizer Ring No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR NEEDLE ROLLER BEARING
1. Remove the 3rd gear needle roller bearing from the input shaft.
  
  Fig 12: Identifying 3rd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 TRANSMISSION HUB SLEEVE
1. Remove the No. 2 transmission hub sleeve, 3 shifting keys, and 3 shifting key springs from the No. 2 transmission clutch hub.
  
  Fig 13: Identifying Transmission Hub Sleeve No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Use a piece of cloth to keep the shifting keys and shifting key springs from flying off.