Input Shaft Disassembly

Transmission. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
Eb61 Manual Transaxle. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. INSPECT 6TH GEAR THRUST CLEARANCE

  2. INSPECT 5TH GEAR THRUST CLEARANCE

  3. INSPECT 4TH GEAR THRUST CLEARANCE

  4. INSPECT 3RD GEAR THRUST CLEARANCE

  5. INSPECT 6TH GEAR RADIAL CLEARANCE

  6. INSPECT 5TH GEAR RADIAL CLEARANCE

  7. INSPECT 4TH GEAR RADIAL CLEARANCE

  8. INSPECT 3RD GEAR RADIAL CLEARANCE

  9. REMOVE REAR INPUT SHAFT BEARING SHAFT SNAP RING

  10. REMOVE 6TH GEAR

  11. REMOVE 6TH GEAR NEEDLE ROLLER BEARING

  12. REMOVE NO. 5 SYNCHRONIZER RING

  13. REMOVE INNER 6TH GEAR BEARING RACE

  14. REMOVE INNER 6TH GEAR BEARING RACE LOCK BALL

  15. REMOVE NO. 3 TRANSMISSION HUB SLEEVE

  16. REMOVE SYNCHROMESH SHIFTING KEY

  17. REMOVE 5TH GEAR

  18. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

  19. REMOVE INNER 5TH GEAR BEARING RACE

  20. REMOVE INNER 5TH GEAR BEARING RACE LOCK BALL

  21. REMOVE 4TH GEAR SUB-ASSEMBLY

  22. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

  23. REMOVE NO. 4 SYNCHRONIZER RING

  24. REMOVE 4TH GEAR BEARING SPACER

  25. REMOVE NO. 2 TRANSMISSION HUB SLEEVE

  26. REMOVE SYNCHROMESH SHIFTING KEY

  27. REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

  28. REMOVE 3RD GEAR SUB-ASSEMBLY

  29. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

  30. REMOVE FRONT INPUT SHAFT BEARING

Input Shaft -- Disassembly



1. INSPECT 6TH GEAR THRUST CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 6th gear thrust clearance.

    Standard clearance:
    0.20 to 0.47 mm (0.00787 to 0.0185 in.)
    Maximum clearance:
    0.47 mm (0.0185 in.)
    If the clearance is more than the maximum, replace the No. 3 transmission clutch hub, 6th gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.


2. INSPECT 5TH GEAR THRUST CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 5th gear thrust clearance.

    Standard clearance:
    0.20 to 0.47 mm (0.00787 to 0.0185 in.)
    Maximum clearance:
    0.47 mm (0.0185 in.)
    If the clearance is more than the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.


3. INSPECT 4TH GEAR THRUST CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 4th gear thrust clearance.

    Standard clearance:
    0.13 to 0.60 mm (0.00512 to 0.0236 in.)
    Maximum clearance:
    0.60 mm (0.0236 in.)
    If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.


4. INSPECT 3RD GEAR THRUST CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 3rd gear thrust clearance.

    Standard clearance:
    0.20 to 0.47 mm (0.00787 to 0.0185 in.)
    Maximum clearance:
    0.47 mm (0.0185 in.)
    If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.


5. INSPECT 6TH GEAR RADIAL CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 6th gear radial clearance between the gear and shaft.

    Standard clearance:
    0.009 to 0.045 mm (0.000355 to 0.00177 in.)
    Maximum clearance:
    0.045 mm (0.00177 in.)
    If the clearance is more than the maximum, replace the 6th gear, 6th gear needle roller bearing, inner 6th gear bearing race or input shaft. Replace the part or parts determined to be the most likely cause of the problem.


6. INSPECT 5TH GEAR RADIAL CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 5th gear radial clearance between the gear and shaft.

    Standard clearance:
    0.009 to 0.045 mm (0.000355 to 0.00177 in.)
    Maximum clearance:
    0.045 mm (0.00177 in.)
    If the clearance is more than the maximum, replace the 5th gear, 5th gear needle roller bearing, inner 5th gear bearing race or input shaft. Replace the part or parts determined to be the most likely cause of the problem.


7. INSPECT 4TH GEAR RADIAL CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

    Standard clearance:
    0.009 to 0.036 mm (0.000355 to 0.00142 in.)
    Maximum clearance:
    0.036 mm (0.00142 in.)
    If the clearance is more than the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.


8. INSPECT 3RD GEAR RADIAL CLEARANCE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a dial indicator, measure the 3rd gear radial clearance.

    Standard clearance:
    0.009 to 0.047 mm (0.0003554 to 0.00185 in.)
    Maximum clearance:
    0.047 mm (0.00185 in.)
    If the clearance is more than the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.


9. REMOVE REAR INPUT SHAFT BEARING SHAFT SNAP RING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a snap ring expander, remove the rear input shaft bearing shaft snap ring.



10. REMOVE 6TH GEAR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Input Shaft Disassembly

  1. Using SST, remove the rear input shaft radial ball bearing and 6th gear from the input shaft.

    SST
    09950-40011(09951-04020,09952-04010,09953-04010,09954-04010,09955-04021,09957-04010,09958-04011)
    09950-60010(09951-00180,09951-00320,09952-06010)


11. REMOVE 6TH GEAR NEEDLE ROLLER BEARING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 pieces of the 6th gear needle roller bearing from the inner 6th gear bearing race.



12. REMOVE NO. 5 SYNCHRONIZER RING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the No. 5 synchronizer ring from the No. 3 transmission clutch hub.



13. REMOVE INNER 6TH GEAR BEARING RACE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the inner 6th gear bearing race from the input shaft.



14. REMOVE INNER 6TH GEAR BEARING RACE LOCK BALL


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Input Shaft Disassembly

  1. Using a magnet hand, remove the inner 6th gear bearing race lock ball from the input shaft.

    Text in Illustration
    *1
    		Magnet Hand


15. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub.



16. REMOVE SYNCHROMESH SHIFTING KEY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 3 synchromesh shifting keys from the No. 3 transmission clutch hub.



17. REMOVE 5TH GEAR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Input Shaft Disassembly

  1. Using SST and a press, press out the No. 3 transmission clutch hub, No. 5 synchronizer ring and 5th gear from the input shaft.

    SST
    09950-00020
    09950-40011(09957-04010)
    09950-60010(09951-00180,09951-00320,09952-06010)
    NOTICE:
    1. Do not tighten SST excessively.
    2. Support the input shaft by hand to prevent it from falling.


18. REMOVE 5TH GEAR NEEDLE ROLLER BEARING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 pieces of the 5th gear needle roller bearing from the inner 5th gear bearing race.



19. REMOVE INNER 5TH GEAR BEARING RACE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the inner 5th gear bearing race from the input shaft.



20. REMOVE INNER 5TH GEAR BEARING RACE LOCK BALL


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Input Shaft Disassembly

  1. Using a magnet hand, remove the inner 5th gear bearing race lock ball from the input shaft.

    Text in Illustration
    *1
    		Magnet Hand


21. REMOVE 4TH GEAR SUB-ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 4th gear from the input shaft.



22. REMOVE 4TH GEAR NEEDLE ROLLER BEARING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 4th gear needle roller bearing from the input shaft.



23. REMOVE NO. 4 SYNCHRONIZER RING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the No. 4 synchronizer ring from the No. 2 transmission clutch hub.



24. REMOVE 4TH GEAR BEARING SPACER


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 4th gear bearing spacer from the No. 2 transmission clutch hub.



25. REMOVE NO. 2 TRANSMISSION HUB SLEEVE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the No. 2 transmission hub sleeve from the No. 2 transmission clutch hub.



26. REMOVE SYNCHROMESH SHIFTING KEY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 3 synchromesh shifting keys from the No. 2 transmission clutch hub.



27. REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a snap ring expander, remove the No. 2 clutch hub setting shaft snap ring.



28. REMOVE 3RD GEAR SUB-ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Input Shaft Disassembly

  1. Using SST, remove the No. 2 transmission clutch hub, No. 3 synchronizer ring and 3rd gear from the input shaft.

    SST
    09950-40011(09951-04020,09952-04010,09953-04010,09954-04020,09955-04021,09957-04010,09958-04011)
    09950-60010(09951-00180,09951-00320,09952-06010)


29. REMOVE 3RD GEAR NEEDLE ROLLER BEARING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 pieces of the 3rd gear needle roller bearing from the input shaft.



30. REMOVE FRONT INPUT SHAFT BEARING


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Eb61 Manual Transaxle.Manual Transaxle System.Input Shaft Disassembly

  1. Using SST and a press, press out the front input shaft bearing from the input shaft.

    SST
    09527-21011
    NOTICE:
    Support the input shaft by hand to prevent it from falling.