Input Shaft: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before assembly.

1. ASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY 
   1. Install the 3 shifting keys and No. 2 hub sleeve to the No. 2 clutch hub.
   2. Install the 2 shifting key springs under the shifting keys
      NOTE: Position the shifting key springs so that their end gaps are not in line.
      Fig 1: Installing Shifting Key Springs Under Shifting Keys

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, SYNCHRONIZER RING AND NO. 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT 
   1. Apply gear oil to the needle roller bearings and install it.
   2. Install the 3rd gear and synchronizer ring.
   3. Install the No. 2 hub sleeve assembly so that the synchronizer ring slots and shifting keys are aligned.
      Fig 2: Installing 3rd Gear And Synchronizer Ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Using a press, install the No. 2 hub sleeve assembly.
      Fig 3: Installing Hub Sleeve Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL SNAP RING 
   1. Select a snap ring that allows the minimum axial play.
      SNAP RING SPECIFICATIONS
      
      

      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)

   2. Using a screwdriver and hammer, tap in the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE (See  DISASSEMBLY   ) 
   Fig 4: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RING, 4TH GEAR AND REAR BALL BEARING 
   1. Install the spacer.
   2. Apply gear oil to the needle roller bearings and install it.
   3. Place the synchronizer ring on the No. 2 hub sleeve assembly and align the synchronizer ring slots with the shifting keys.
   4. Install the 4th gear.
      Fig 5: Installing Spacer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Using SST and a press, install the rear ball bearing.

      SST 09608-00071

      Fig 6: Installing Rear Ball Bearing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL SNAP RING 
   1. Select a snap ring that allows the minimum axial play.
      SNAP RING SPECIFICATIONS
      
      

      Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
      A	2.29 (0.0902)	D	2.47 (0.0972)
      B	2.35 (0.0925)	E	2.53 (0.0996)
      C	2.41 (0.0949)	F	2.59 (0.1020)

   2. Using a screwdriver and hammer, tap in the snap ring.
7. INSPECT 4TH GEAR THRUST CLEARANCE (See  DISASSEMBLY   ) 
   Fig 7: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002