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Input Shaft: Disassembly

  1. 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 1: Measuring 4Th Gear Thrust Clearance
      G04831836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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 2: Measuring 3Rd Gear Thrust Clearance
      G04831837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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 3: Measuring 4Th Gear Radial Clearance Between Gear And Shaft
      G04831838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.

  4. 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 4: Measuring 3Rd Gear Radial Clearance
      G04831839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.

  5. REMOVE 4TH GEAR 
    1. Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.

      HINT:

      Use a piece of cloth to keep the snap ring from flying off.

      Fig 5: Removing Input Shaft Rear Bearing Shaft Snap Ring From Input Shaft
      G04831840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the input shaft rear radial ball bearing and 4th gear from the input shaft.

      SST 09950-00020 

      HINT:

      • Do not tighten SST excessively.
      • Support the input shaft assembly by hand to prevent it from dropping off.
        Fig 6: Removing Input Shaft Rear Radial Ball Bearing And 4Th Gear From Input Shaft
        G04831841Courtesy 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 7: Identifying 4Th Gear Needle Roller Bearing
      G04831842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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
      G04831843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE 3RD GEAR 
    1. Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.

      HINT:

      Use a piece of cloth to keep the snap ring from flying off.

      Fig 9: Removing No. 2 Clutch Hub Setting Shaft Snap Ring From Input Shaft
      G04831844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the No. 2 transmission clutch hub and 3rd gear from the input shaft.

      SST 09950-00020 

      NOTE:
      • Do not tighten SST excessively.
      • Support the input shaft by hand to prevent it from dropping off.
        Fig 10: Removing No. 2 Transmission Clutch Hub And 3Rd Gear From Input Shaft
        G04831845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE 3RD GEAR SYNCHRONIZER RING 
    1. Remove the 3rd gear synchronizer ring from the 3rd gear.
      Fig 11: Removing 3Rd Gear Synchronizer Ring From 3Rd Gear
      G04831846Courtesy 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 12: Removing 3Rd Gear Needle Roller Bearing From Input Shaft
      G04831847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. 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.
      NOTE: Use a piece of cloth to keep the shifting keys and shifting key springs from flying off.
      Fig 13: Removing No. 2 Transmission Hub Sleeve, 3 Shifting Keys, And 3 Shifting Key Springs From No. 2 Transmission Clutch Hub
      G04831848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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