Input Shaft: Disassembly

WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

MEASURE 3RD AND 4TH GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.

Fig 1: Measuring Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Maximum clearance:

3rd gear: 0.35 mm (0.0138 in.)

4th gear: 0.57 mm (0.0224 in.)
CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.

Fig 2: Measuring Radial Clearance Between Gear & Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Maximum clearance:

3rd gear: 0.053 mm (0.0021 in.)

4th gear: 0.051 mm (0.0020 in.)

If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
REMOVE REAR BEARING AND 4TH GEAR
Using SST and a press, remove the rear bearing and 4th gear.

SST 09950-00020

Fig 3: Removing Rear Bearing & 4th Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE 2 NEEDLE ROLLER BEARINGS, SPACER AND SYNCHRONIZER RING
REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
REMOVE NO. 2 HUB SLEEVE ASSEMBLY, SYNCHRONIZER RING AND 3RD GEAR
Using a press, remove the No. 2 hub sleeve assembly, synchronizer ring and 3rd gear.

Fig 4: Removing No. 2 Hub Sleeve Assembly, Synchronizer Ring & 3rd Gear

REMOVE 2 NEEDLE ROLLER BEARINGS
DISASSEMBLY NO. 2 HUB SLEEVE ASSEMBLY
1. Remove the No. 2 hub sleeve from the No. 2 clutch hub.
2. Remove the 3 shifting keys and springs from the No. 2 clutch hub.
REMOVE INPUT SHAFT FRONT BEARING INNER RACE
Using a screwdriver and hammer, remove the input shaft front bearing inner race.