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Input Shaft: Reassembly

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT INPUT SHAFT (See INSPECTION  )
  2. INSPECT 4TH GEAR (See INSPECTION  )
  3. INSPECT 3RD GEAR (See INSPECTION  )
  4. INSPECT 4TH GEAR SYNCHRONIZER RING (See INSPECTION  )
  5. INSPECT 3RD GEAR SYNCHRONIZER RING (See INSPECTION  )
  6. INSPECT TRANSMISSION HUB SLEEVE NO. 2 (See INSPECTION  )
  7. 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 1: Installing 3 Synchronizer Shifting Key Springs
      G04464465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL 3RD GEAR NEEDLE ROLLER BEARING 
    1. Coat the 3rd gear needle roller bearing with gear oil, install it to the input shaft.
      Fig 2: Installing 3rd Gear Needle Roller Bearing
      G04464466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL 3RD GEAR 
    1. Coat the 3rd gear with gear oil, install it to the input shaft.
      Fig 3: Installing 3rd Gear
      G04464467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL 3RD GEAR SYNCHRONIZER RING 
    1. Coat the 3rd gear synchronizer ring with gear oil, install it to the 3rd gear.
      Fig 4: Installing 3rd Gear Synchronizer Ring
      G04464468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. 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 5: Installing Transmission Clutch Hub No.2
      G04464469Courtesy 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: 

      SNAP RING THICKNESS

      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 6: Installing Snap Ring
      G04464470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. 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 7: Installing 4th Gear Synchronizer Ring
      G04464471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 8: Installing 4th Gear Needle Roller Bearing
      G04464472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL 4TH GEAR 
    1. Coat the 4th gear with gear oil, install it to the input shaft.
      Fig 9: Installing 4th Gear
      G04464473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL INPUT SHAFT BEARING 
    1. Using SST and a press, install the input shaft bearing to the input shaft.

      SST 09608-04031 

      Fig 10: Installing Input Shaft Bearing
      G04464474Courtesy 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: 

      Fig 11: Installing Snap Ring
      G04464475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS

      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.
  16. INSPECT 3RD GEAR RADIAL CLEARANCE (See INSPECTION  )
  17. INSPECT 4TH GEAR RADIAL CLEARANCE (See INSPECTION  )
  18. INSPECT 3RD GEAR THRUST CLEARANCE (See INSPECTION  )
  19. INSPECT 4TH GEAR THRUST CLEARANCE (See INSPECTION  )
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