Input Shaft: Disassembly

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

INSPECT 6TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 6th gear thrust clearance.
  Standard clearance:
  
  0.20 to 0.48 mm (0.0079 to 0.0189 in.)
  
  Maximum clearance:
  
  0.48 mm (0.0189 in.)
  
  If the clearance is outside the specification, replace the defective gear, thrust washer or shaft.
  
  Fig 1: Inspecting 6th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 3rd gear thrust clearance.
  Standard clearance:
  
  0.19 to 0.51 mm (0.0075 to 0.0201 in.)
  
  Maximum clearance:
  
  0.51 mm (0.0201 in.)
  
  If the clearance is outside the specification, replace the defective gear, thrust washer, clutch hub or shaft.
  
  Fig 2: Inspecting 3rd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 4th gear thrust clearance.
  Standard clearance:
  
  0.12 to 0.38 mm (0.0047 to 0.0150 in.)
  
  Maximum clearance:
  
  0.38 mm (0.0150 in.)
  
  If the clearance is outside the specification, replace the defective gear, clutch hub or shaft.
  
  Fig 3: Measuring 4th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 6TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 6th gear radial clearance.
  Standard clearance:
  
  0.015 to 0.065 mm (0.0006 to 0.0026 in.)
  
  Maximum clearance:
  
  0.065 mm (0.0026 in.)
  
  If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
  
  Fig 4: Measuring 6th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 3rd gear radial clearance.
  Standard clearance:
  
  0.015 to 0.067 mm (0.0006 to 0.0026 in.)
  
  Maximum clearance:
  
  0.067 mm (0.0026 in.)
  
  If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
  
  Fig 5: Measuring 3rd Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 4TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 4th gear radial clearance.
  Standard clearance:
  
  0.013 to 0.026 mm (0.0005 to 0.0010 in.)
  
  Maximum clearance:
  
  0.026 mm (0.0010 in.)
  
  If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
  
  Fig 6: Measuring 4th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 TRANSMISSION CLUTCH HUB SHAFT SNAP RING
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Use a shop rag or a piece of cloth to prevent the snap ring from flying off.
  
  Fig 7: Removing No. 3 Transmission Clutch Hub Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 6TH GEAR
1. Using SST and a press, remove the No. 3 transmission clutch hub, hub sleeve, synchronizer ring and 6th gear from the input shaft.
  SST 09950-00020, 09950-70010 (09951 -07200), 09950-60010 (09951-00300)
  NOTE:
  - Do not tighten SST excessively.
  - Support the gear and input shaft by hand so they do not fall off.
    
    Fig 8: Removing 6th Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 6TH GEAR NEEDLE ROLLER BEARING
1. Remove the 6th gear needle roller bearing from the input shaft.
  
  Fig 9: Removing 6th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPACER
1. Remove the spacer from the input shaft.
  
  Fig 10: Removing Spacer From Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR THRUST WASHER SHAFT SNAP RING
1. Using a snap ring expander, remove the snap ring from the input shaft.
  
  Fig 11: Removing Gear Thrust Washer Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR THRUST WASHER
1. Remove the 3rd gear thrust washer from the input shaft.
  
  Fig 12: Removing 3rd Gear Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR
1. Remove the 3rd gear from the input shaft.
  
  Fig 13: Removing 3rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STRAIGHT PIN
1. Remove the straight pin from the input shaft.
  
  Fig 14: Removing Straight Pin Onto Input Shaft
  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 15: Removing 3rd Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPACER
1. Remove the spacer from the input shaft.
  
  Fig 16: Removing Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 SYNCHRONIZER RING SET
1. Remove the No. 2 synchronizer ring set from the input shaft.
  
  Fig 17: Removing No. 2 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING
1. Using a snap ring expander, remove the snap ring from the input shaft.
  
  Fig 18: Removing No. 2 Clutch Hub Setting Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR
1. Using SST and a press, remove the No. 2 transmission clutch hub, hub sleeve, synchronizer ring and 4th gear from the input shaft.
  SST 09950-00020
  
  NOTE: Support the gear and input shaft by hand so they do not fall off.
  
  Fig 19: Removing 4th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR NEEDLE ROLLER BEARING
1. Remove the 4th gear needle roller bearing from the input shaft.
  
  Fig 20: Removing 4th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT FRONT BEARING SNAP RING
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Use a shop rag or a piece of cloth to prevent the snap ring from flying off.
  
  Fig 21: Removing Input Shaft Front Bearing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT FRONT BEARING
1. Using SST and a press, remove the input shaft front bearing from the input shaft.
  SST 09950-00020
  
  NOTE: Support the gear and input shaft by hand so they do not fall off.
  
  Fig 22: Removing Input Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 TRANSMISSION CLUTCH HUB
1. Remove the clutch hub, 3 synchromesh shifting keys, 3 balls and 3 springs from the hub sleeve.
  HINT:
  
  Use a shop rag or a piece of cloth to prevent the ball and spring from flying off.
REMOVE NO. 3 TRANSMISSION CLUTCH HUB
1. Perform the same procedures as for the No. 2 transmission clutch hub.
  
  Fig 23: Removing No. 3 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002