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Input Shaft ASSY (C59): Overhaul

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  1. INSPECT 4th GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 4th gear thrust clearance.
    THRUST CLEARANCE REFERENCE

    Standard clearance: mm (in.) Maximum clearance: mm (in.)
    0.10 to 0.55 (0.0039 to 0.0217) 0.55 (0.0217)
    Fig 1: Measuring 4th Gear Thrust Clearance
    G02614867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT 3rd GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear thrust clearance.
    THRUST CLEARANCE REFERENCE

    Standard clearance: mm (in.) Maximum clearance: mm (in.)
    0.10 to 0.35 (0.0039 to 0.0138) 0.35 (0.0138)
    Fig 2: Measuring 3rd Gear Thrust Clearance
    G02614868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT 4th GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 4th gear radial clearance.
    RADIAL CLEARANCE REFERENCE

      Standard clearance: mm (in.) Maximum clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023) 0.058 (0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022) 0.056 (0.0022)

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

    Fig 3: Measuring 4th Gear Radial Clearance
    G02614869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT 3rd GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear radial clearance.
    RADIAL CLEARANCE REFERENCE

      Standard clearance: mm (in.) Maximum clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023) 0.058 (0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022) 0.0056 (0.0022)

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

    Fig 4: Measuring 3rd Gear Radial Clearance
    G02614870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE 4th GEAR 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      Use a shop rag to keep the snap ring from flying.

      Fig 5: Removing Snap Ring
      G02614871Courtesy 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

    NOTE:
    • Do not tighten SST excessively.
    • Support the input shaft assy by hand so that it will not be dropped off.
    Fig 6: Removing Input Shaft Rear Radial Ball Bearing
    G02614872Courtesy 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: Removing 4th Gear Needle Roller Bearing
    G02614873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE 4th GEAR SYNCHRONIZER RING 
    1. Remove the 4th gear synchronizer ring from the transmission clutch hub No.2.
    Fig 8: Removing 4th Gear Synchronizer Ring
    G02614874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE 3rd GEAR 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      Use a shop rag to keep the snap ring from flying.

      Fig 9: Removing Snap Ring
      G02614875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the transmission clutch hub No.2 and 3rd gear from the input shaft.

      SST 09950-00020

    NOTE:
    • Do not tighten SST excessively.
    • Support the input shaft by hand so that it will not be dropped off.
    Fig 10: Removing Transmission Clutch Hub
    G02614876Courtesy 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
    G02614877Courtesy 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
    G02614878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSMISSION HUB SLEEVE NO.2 
    1. Remove the transmission hub sleeve No.2, 3 shifting key No.2 and 3 shifting key spring No.2 from the transmission clutch hub No.2.

    HINT:

    Using a shop rag to prevent the shifting key and shifting key spring from being scattered.

    Fig 13: Removing Transmission Hub Sleeve Shifting Key
    G02614879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT INPUT SHAFT 
    1. Using a dial indicator, check the shaft runout.

      Maximum runout: 0.015 mm (0.0006 in.) 

      If the runout exceeds the maximum, replace the input shaft.

      Fig 14: Checking Shaft Runout
      G02614880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a micrometer, measure the outer diameter of the input shaft journal surface.
    OUTER DIAMETER REFERENCE

    Part Standard outer diameter: mm (in.) Minimum outer diameter: mm (in.)
    A 24.885 to 24.900 (0.9803) 24.885 (0.9797)
    B 28.985 to 29.000 (1.1411 to 1.1417) 28.985 (1.1411)
    C 30.985 to 31.000 (1.2198 to 1.2204) 30.985 (1.2198)
    D 24.985-25.00 (0.9836 to 0.9842) 24.985 (0.9836)

    If the outer diameter is below the minimum, replace the input shaft.

    Fig 15: Measuring Outer Diameter
    G02614881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT 4th GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 4th gear.

      Standard inside diameter: 34.015 to 34.031 mm (1.3391 to 1.3398 in.) 

      Maximum inside diameter: 34.031 mm (1.3398 in.) 

    If the inside diameter exceeds the maximum, replace the 4th gear.

    Fig 16: Measuring Inside Diameter Of Gear
    G02614882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT 3rd GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.

      Standard inside diameter: 36.015 to 36.031 mm (1.4179 to 1.4185 in.) 

      Maximum inside diameter: 36.031 mm (1.4185 in.) 

    If the inside diameter exceeds the maximum, replace the 3rd gear.

    Fig 17: Measuring Inside Diameter Of Gear
    G02614883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT 4th GEAR SYNCHRONIZER RING 
    1. Check for wear or damage.
    2. Coat the 4th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks.

      If the synchronizer outer ring does not lock, replace the ring or the 4th gear.

      Fig 18: Inspecting 4th Gear Synchronizer Ring
      G02614884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a feeler gauge, measure the clearance between the 4th gear synchronizer ring back and 4th gear spline end.

      Minimum clearance: 0.65 mm (0.0256 in.) 

    If the clearance below than the minimum, replace the 4th gear synchronizer ring.

    Fig 19: Measuring Clearance
    G02614885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSPECT 3rd GEAR SYNCHRONIZER RING 
    1. Check for wear or damage.
    2. Coat the 3rd gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks.

      If the synchronizer outer ring does not lock, replace the ring or the 3rd gear.

      Fig 20: Inspecting 3rd Gear Synchronizer Ring
      G02614886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a feeler gauge, measure the clearance between 3rd gear synchronizer ring back and 3rd gear spline end.

      Minimum clearance: 0.75 mm (0.0295 in.) 

    If the clearance below than the minimum, replace the 3rd gear synchronizer ring.

    Fig 21: Measuring Clearance
    G02614887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT TRANSMISSION HUB SLEEVE NO.2 
    1. Check the sliding condition between the transmission hub sleeve No.2 and transmission clutch hub No.2.
    2. Check that the spline gear's edges of the transmission hub sleeve No.2 is not worn down.
      Fig 22: Inspecting Transmission Hub Sleeve
      G02614888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using vernier calipers, measure the width of the transmission hub sleeve No.2 groove (B) and the thickness of the claw part on the gear shift fork No.2 (A), and calculate the clearance.

      Standard clearance (B - A): 0.15 to 0.35 mm (0.0059 to 0.0137 in.) 

    If the clearance is out of specification, replace the transmission hub sleeve No.2 and gear shift fork No.2.

    Fig 23: Measuring Width Of Transmission Hub Sleeve
    G02614889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL TRANSMISSION HUB SLEEVE NO.2 
    1. Coat the transmission hub sleeve No.2 with gear oil, install it to the transmission clutch hub No.2.
      NOTE: Do not set the transmission clutch hub sleeve No.2 and the transmission clutch hub No.2 in incorrect orientation.
    2. Using a screwdriver, install the 3 synchromesh key springs with 3 synchromesh shifting keys to the transmission clutch hub No.2.
    Fig 24: Installing Synchromesh Key Springs
    G02614890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL 3rd GEAR NEEDLE ROLLER BEARING 
    1. Coat the 3rd gear needle roller bearing with gear oil, install it to the input shaft.
    Fig 25: Installing Needle Roller Bearing
    G02614891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL 3rd GEAR 
    1. Coat the 3rd gear with gear oil, install it to the input shaft.
    Fig 26: Installing 3rd Gear
    G02614892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL 3rd GEAR SYNCHRONIZER RING 
    1. Coat the 3rd gear synchronizer ring with gear oil, install it to the 3rd gear.
    Fig 27: Installing 3rd Gear Synchronizer Ring
    G02614893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL TRANSMISSION CLUTCH HUB NO.2 
    1. Using SST and a press, install the transmission clutch hub No.2 to the input shaft.

      SST 09316-60011 (09316-00021)

      Fig 28: Installing Transmission Clutch Hub
      G02614894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No.2 below 0.1 mm (0.004 in.).
      SNAP RING THICKNESS SPECIFICATION

      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)
    3. Using a brass bar and a hammer, tap in the snap ring.
    Fig 29: Installing Snap Ring
    G02614895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Take care not to damage the journal surface of the input shaft.
  23. INSTALL 4th GEAR SYNCHRONIZER RING 
    1. Coat the 4th gear synchronizer ring with gear oil, install it to the transmission clutch hub No.2.
    Fig 30: Installing 4th Gear Synchronizer Ring
    G02614896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL 4th GEAR NEEDLE ROLLER BEARING 
    1. Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil, install them to the input shaft.
    Fig 31: Installing 4th Gear Needle Roller Bearing
    G02614897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL 4th GEAR 
    1. Coat the 4th gear with gear oil, install it to the input shaft.
    Fig 32: Installing 4th Gear
    G02614898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, install the input shaft rear radial ball bearing to the input shaft.

      SST 09636-20010

      Fig 33: Installing Input Shaft Rear Radial Ball Bearing
      G02614899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring from the table below that will make the thrust clearance of the input shaft rear radial ball bearing below 0.1 mm (0.004 in.).
      SNAP RING THICKNESS SPECIFICATION

      Mark Thickness: mm (in.) Mark Thickness: mm (in.)
      0 2.29 (0.0901) 3 2.47 (0.0972)
      1 2.35 (0.0925) 4 2.53 (0.0996)
      2 2.41 (0.0948) 5 2.59 (0.1019)
    3. Using a brass bar and a hammer, tap in the snap ring.
    Fig 34: Installing Snap Ring
    G02614900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Take care not to damage the journal surface of the snap ring.
  27. INSPECT 3rd GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear radial clearance.
    RADIAL CLEARANCE REFERENCE

      Standard clearance: mm (in.) Maximum clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023) 0.058 (0.0023)
    NSK madS 0.015 to 0.056 (0.0006 to 0.0022 0.0056 (0.0022)

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

    Fig 35: Measuring Gear Radial Clearance
    G02614901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSPECT 4th GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 4th gear radial clearance.
    RADIAL CLEARANCE REFERENCE

      Standard clearance: Maximum clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023) 0.058 (0.0023)
    NSK mad 0.015 to 0.056 (0.0006 to 0.0022) 0.056 (0.0022)

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

    Fig 36: Measuring Gear Radial Clearance
    G02614902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSPECT 3rd GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear thrust clearance.
    THRUST CLEARANCE REFERENCE

    Standard clearance: mm (in.) Maximum clearance: mm (in.)
    0.10 to 0.35 (0.0039 to 0.0138) 0.10 (0.0138)
    Fig 37: Measuring Gear Thrust Clearance
    G02614903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSPECT 4th GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 4th gear thrust clearance.
    THRUST CLEARANCE REFERENCE

    Standard clearance: mm (in.) Maximum clearance: mm (in.)
    0.10 to 0.55 (0.0039 to 0.0217) 0.55 (0.0217)
    Fig 38: Inspecting Gear Thrust Clearance
    G02614904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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