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Input Shaft ASSY (C60): Overhaul

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  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 (0.0039 to 0.0217 in.) 

    Fig 1: Measuring Gear Thrust Clearance
    G02614906Courtesy 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 (0.0039 to 0.0138 in.) 

    Fig 2: Measuring Gear Thrust Clearance
    G02614907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT 4th GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 4th gear radial clearance.
    Fig 3: Measuring Gear Radial Clearance
    G02614908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    STANDARD CLEARANCE REFERENCE

    Bearing Clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022)

    If the clearance is out of specification, replace the 4th gear needle roller bearing.

  4. INSPECT 3rd GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear radial clearance.
    STANDARD CLEARANCE REFERENCE

    Bearing Clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022)

    If the clearance is out of specification, replace the 3rd gear needle roller bearing.

    Fig 4: Measuring Gear Radial Clearance
    G02614909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE 4th GEAR 
    1. Using 2 screwdrivers and a hammer, remove the input shaft bearing shaft snap ring.

      HINT:

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

      Fig 5: Removing Input Shaft Bearing Shaft Snap Ring
      G02614910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the input shaft bearing with 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 Bearing
    G02614911Courtesy 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 Gear Needle Roller Bearing
    G02614912Courtesy 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 Gear Synchronizer Ring
    G02614913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE 3rd GEAR 
    1. Using 2 screwdrivers and a hammer, remove the clutch hub No.2 shaft snap ring from the input shaft.

      HINT:

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

      Fig 9: Removing Clutch Hub
      G02614914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the transmission clutch hub No.2 with 3rd gear from the input shaft.

      SST 09950-00020

    NOTE: Do not tighten SST excessively.
    Fig 10: Removing Transmission Clutch Hub
    G02614915Courtesy 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 Gear Synchronizer Ring
    G02614916Courtesy 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 Gear Needle Roller Bearing
    G02614917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSMISSION HUB SLEEVE NO.2 
    1. Remove the transmission hub sleeve No.2,3 synchronizer shifting keys and 3 synchronizer shifting key springs from the transmission clutch hub No.2.

    HINT:

    Use a shop rag to keep the synchromesh shifting key and spring from flying.

    Fig 13: Removing Transmission Hub Sleeve
    G02614918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT INPUT SHAFT 
    1. Using a dial indicator and 2 V-blocks, measure the shaft runout.

      Maximum runout: 0.015 mm (0.0006 in.) 

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

      Fig 14: Measuring Shaft Runout
      G02614919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a micrometer, measure the outer diameter of the input shaft journal surface.
    OUTER DIAMETER REFERENCE

    Part New shaft: mm (in.) Minimum outer diameter: mm (in.)
    A 21.991 to 21.006 (0.8658 to 0.8270) 21.991 (0.8658)
    B 24.885 to 24.900 (0.9797 to 0.9803) 24.885 (0.9797)
    C 28.985 to 29.000 (1.1411 to 1.1417) 28.985 (1.1411)
    D 30985 to 31.000 (1.2199 to 1.2205) 30.985 (1.2199)

    If the outer diameter is less than the minimum, replace the input shaft.

    Fig 15: Measuring Outer Diameter
    G02614920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT 4th GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
    INSIDE DIAMETER REFERENCE

    New gear: mm (in.) Maximum inside diameter: mm (in.)
    34.015 to 34.031 (1.3390 to 1.33985) 34.031 (1.3398)

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

    Fig 16: Measuring Inside Diameter
    G02614921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT 3rd GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.
    INSIDE DIAMETER REFERENCE

    New gear: mm (in.) Maximum inside diameter: mm (in.)
    36.015 to 36.031 (1.4179 to 1.4185) 36.031 (1.4185)

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

    Fig 17: Measuring Inside Diameter
    G02614922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT 4th GEAR SYNCHRONIZER RING 
    1. 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 ring does not lock, replace the ring or 4th gear.

      Fig 18: Inspecting Gear Synchronizer Ring
      G02614923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a feeler gauge, measure the clearance between the 4th gear synchronizer ring back and 4th gear spline end.

      Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.0650 in.) 

    If the clearance is out of specification, replace the 4th gear synchronizer ring.

    Fig 19: Measuring Clearance
    G02614924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSPECT 3rd GEAR SYNCHRONIZER RING 
    1. 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 ring does not lock, replace the ring or 3rd gear.

      Fig 20: Inspecting Gear Synchronizer Ring
      G02614925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a feeler gauge, measure the clearance between the 3rd gear synchronizer ring back and 3rd gear spline end.

      Standard clearance: 0.65 to 1.75 mm (0.0256 to 0.0689 in.) 

    If the clearance is out of specification, replace the 3rd gear synchronizer ring.

    Fig 21: Measuring Clearance
    G02614926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT TRANSMISSION HUB SLEEVE NO.2 
    1. Check the sliding condition between the transmission hub No.2 and transmission hub sleeve No.2.
    2. Check that the spline gear's edges of the transmission hub sleeve No.2 is not worn down.
      Fig 22: Checking Sliding Condition
      G02614927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove (B) and the thickness of the claw part on the gear shift fork No.1 (A), and calculate the clearance.

      Standard clearance (B - A): 0.15 to 0.35 mm (0.0059 to 0.0138 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
    G02614928Courtesy 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 hub sleeve No.2 and the transmission clutch hub No.2 in incorrect orientation.
    2. Using a screwdriver, install the 3 synchronizer shifting key springs with 3 synchronizer shifting keys.
    Fig 24: Installing Synchronizer Shifting Key Springs
    G02614929Courtesy 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 Gear Needle Roller Bearing
    G02614930Courtesy 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
    G02614931Courtesy 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 Gear Synchronizer Ring
    G02614932Courtesy 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 09309-36100 (09309-03610), 09950-60010 (09951-00450)

      Fig 28: Installing Transmission Clutch Hub
      G02614933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring that will allow minimum axial play.

      Standard clearance: 0.1 mm (0.004 in.) or less 

      SNAP RING THICKNESS SPECIFICATION

      Part No. Thickness: mm (in.) Mark
      90520-27046 2.30 (0.0906) 0
      90520-27047 2.36 (0.0929) 1
      90520-27048 2.42 (0.0953) 2
      90520-27049 2.48 (0.0976) 3
      90520-27050 2.54 (0.1000) 4
      90520-27051 2.60 (0.1024) 5
    3. Using a brass bar and a hammer, install the snap ring to the input shaft.
    Fig 29: Installing Snap Ring
    G02614934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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
    G02614935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL 4th GEAR NEEDLE ROLLER BEARING 
    1. Coat the 4th gear bearing spacer and 4th gear needle roller bearing with gear oil, install them to the input shaft.
    Fig 31: Installing Gear Needle Roller Bearing
    G02614936Courtesy 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 Gear
    G02614937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL INPUT SHAFT BEARING 
    1. Using SST and a press, install the input shaft bearing to the input shaft.

      SST 09608-04031

      Fig 33: Installing Input Shaft Bearing
      G02614938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring that will allow minimum axial play.

      Standard clearance: 0.1 mm (0.004 in.) or less 

      Fig 34: Installing Snap Ring
      G02614939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS SPECIFICATION

      Part No. Thickness: mm (in.) Mark
      90520-22006 2.29 (0.0902) A
      90520-22007 2.35 (0.0925) B
      90520-22008 2.41 (0.0949) C
      90520-22009 2.47 (0.0972) D
      90520-22010 2.53 (0.0996) E
      90520-22011 2.59 (0.1020) F
    3. Using a brass bar and a hammer, install the snap ring to the input shaft.
  27. INSPECT 3rd GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear radial clearance.
    STANDARD CLEARANCE REFERENCE

    Bearing Clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022)

    If the clearance is out of specification, replace the 3rd gear needle roller bearing.

    Fig 35: Measuring Gear Radial Clearance
    G02614940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSPECT 4th GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 4th gear radial clearance.
    STANDARD CLEARANCE REFERENCE

    Bearing Clearance: mm (in.)
    KOYO made 0.015 to 0.058 (0.0006 to 0.0023)
    NSK made 0.015 to 0.056 (0.0006 to 0.0022)

    If the clearance is out of specification, replace the 4th gear needle roller bearing.

    Fig 36: Measuring Gear Radial Clearance
    G02614941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSPECT 3rd GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 3rd gear thrust clearance.

      Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 in.) 

    Fig 37: Measuring Gear Thrust Clearance
    G02614942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSPECT 4th GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 4th gear thrust clearance.

      Standard clearance: 0.10 to 0.55 mm (0.0039 to 0.0217 in.) 

    Fig 38: Measuring Gear Thrust Clearance
    G02614943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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