TOYOTA SUPRA 1995 Service Repair Manual

(d) Using a feeler gauge, measure the clearance between the
synchronizer ring back and gear spline end.
Minimum clearance:
0.5 mm (0.020 in.)
HINT: When replacing either a synchronizer ring or gear, ap-
ply a small amount of fine lapping compound between the
synchronizer ring and gear cone.
Lightly rub the synchronizer ring and gear cone together.
NOTICE:
wWhen replacing both the synchronizer ring and gear,
there is no need to apply any compound or to rub them
together.
wNOTICE: Ensure the fine lapping compound is
completely washed off after rubbing.
BEARING REPLACEMENT
IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the bearing.
(c) Using SST and a press, install a new bearing.
SST 09506±35010
(d) Select a snap ring that will allow minimum axial play.
 
 Mark
 
 Thickness mm (in.)
 1 2.05±2.10 (0.0807±0.0827)
 2 2.10±2.15 (0.0827±0.0846)
 3 2.15±2.20 (0.0846±0.0866)
 4 2.20±2.25 (0.0866±0.0886)
 5 2.25±2.30 (0.0886±0.0906)
 11 2.30±2.35 (0.0906±0.0925) 12 2.35±2.40 (0.0925±0.0945)
(e) Using a snap ring expander, install the snap ring.
± W58 MANUAL TRANSMISSIONINPUT SHAFTMT1±25

OUTPUT SHAFT
COMPONENTS
OUTPUT SHAFT DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of each
gear.
Standard clearance:
0.10±0.25 mm (0.0039±0.0098 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
MT1±26± W58 MANUAL TRANSMISSIONOUTPUT SHAFT

2. INSPECT EACH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of each
gear.
Standard clearance:
1st and 2nd gear
0.009±0.060 mm (0.0004±0.0024 in.)
3rd gear
0.015±0.066 mm (0.0006±0.0026 in.)
Maximum clearance:
1st and 2nd gear
0.150 mm (0.0059 in.)
3rd gear
0.200 mm (0.0079 in.)
If the clearance exceeds the maximum, replace the gear,
shaft or needle roller bearing.
3. REMOVE OUTPUT SHAFT CENTER BEARING AND 1ST
GEAR ASSEMBLY
(a) Shift the No.1 hub sleeve onto the 2nd gear.
(b) Using a press, remove the center bearing, 1st gear, needle
roller bearing, inner race and synchronizer ring.
4. REMOVE LOCKING BALL
Using a magnetic finger, remove the locking ball.
5. REMOVE NO. 1 HUB SLEEVE ASSEMBLY, 2 ND GEAR
AND NEEDLE ROLLER BEARING
Using a press, remove the parts from the shaft as an assem-
bly.
6. REMOVE NO.1 HUB SLEEVE, SHIFTING KEYS AND
SPRINGS FROM NO. 1 CLUTCH HUB
(a) Remove the No. 1 clutch hub from the No. 1 hub sleeve.
± W58 MANUAL TRANSMISSIONOUTPUT SHAFTMT1±27

(b) Push the shifting key spring with a screwdriver, remove the
3 shifting keys and key springs.
7. REMOVE NO.2 HUB SLEEVE ASSEMBLY AND 3RD
GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the No.2 hub sleeve, synchronizer
ring and 3rd gear.
8. REMOVE NO.2 HUB SLEEVE, SHIFTING KEYS AND
SPRINGS FROM NO.2 CLUTCH HUB
(a) Remove the No. 2 clutch hub from the No. 2 hub sleeve.
(b) Push the shifting key spring with a screwdriver, remove the
3 shifting keys and key springs.
OUTPUT SHAFT COMPONENT PARTS
INSPECTION
1. INSPECT 1ST GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing it to
the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of
fine lapping compound between the synchronizer ring and
gear cone.
Lightly rub the synchronizer ring and gear cone together.
NOTICE: Ensure the fine lapping compound is complete-
ly washed off after rubbing.
(c) Check again the braking effect of the synchronizer ring. If it
does not lock, replace the synchronizer ring. MT1±28
± W58 MANUAL TRANSMISSIONOUTPUT SHAFT

(d) Using a feeler gauge, measure the clearance between the
synchronizer ring back and gear spline end.
Minimum clearance:
0.5 mm (0.020 in.)
HINT: When replacing either a synchronizer ring or gear, ap-
ply a small amount of fine lapping compound between the
synchronizer ring and gear cone.
Lightly rub the synchronizer ring and gear cone together.
NOTICE:
wWhen replacing both the synchronizer ring and gear,
there is no need to apply any compound or to rub them
together.
wEnsure the fine lapping compound is completely washed
off after rubbing.
2. INSPECT 2 ND AND 3 RD GEAR SYNCHRONIZER RINGS
(a) Check for wear or damage.
(b) Install the synchronizer inner ring, middle ring and outer ring
to each gear.
(c) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing it to
the gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between the
synchronizer ring back and the gear spline end.
Minimum clearance:
0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the syn-
chronizer ring.
± W58 MANUAL TRANSMISSIONOUTPUT SHAFTMT1±29

3. INSPECT CLEARANCE OF SHIFT FORKS AND HUB
SLEEVES
Using a feeler gauge, measure the clearance between the
hub sleeve and shift fork.
Maximum clearance:
1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork
or hub sleeve.
4. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using vernier calipers, measure the output shaft flange
thickness.
Minimum thickness:
5.60 mm (0.2205 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using vernier calipers, measure the inner race flange
thickness.
Minimum thickness:
4.78 mm (0.1882 in.)
If the thickness is less than the minimum, replace the inner
race.
(c) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
2nd gear
42.975 mm (1.6919 in.)
3rd gear
31.969 mm (1.2586 in.)
If the outer diameter is less than the minimum, replace the
output shaft.
(d) Using a micrometer, measure the outer diameter of the inner
race.
Minimum diameter:
42.975 mm (1.6919 in.)
If the outer diameter is less than the minimum, replace the in-
ner race. MT1±30
± W58 MANUAL TRANSMISSIONOUTPUT SHAFT

(e) Using a dial indicator, check the shaft runout.
Maximum runout:
0.06 mm (0.0024 in.)
If the runout exceeds the maximum, replace the output shaft.
OUTPUT SHAFT ASSEMBLY
HINT: Coat all of the sliding and rotating surface with gear oil
before assembly.
1. INSTALL NO.1 AND NO.2 CLUTCH HUB INTO HUB
SLEEVE
(a) Install the 3 shifting key springs to the clutch hub.
(b) While pushing the shifting key spring with a screw±driver,
install the 3 shifting keys.
(c) While pushing the 3 shifting keys, install the clutch hub to the
hub sleeve, as shown.
2. INSTALL 3RD GEAR AND NO.2 CLUTCH HUB ON
OUTPUT SHAFT
(a) Apply gear oil to the shaft.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
± W58 MANUAL TRANSMISSIONOUTPUT SHAFTMT1±31

(c) Using a press, install the 3rd gear and No.2 clutch hub.
3. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.
 Mark Thickness mm (in.)
 C±1 1.75±1.80 (0.0689±0.0709)
 D 1.80±1.85 (0.0709±0.0728)
 11 1.86±1.91 (0.0732±0.0752) 12 1.92±1.97 (0.0756±0.0776) 
 13
 
 1.98±2.03 (0.0780±0.0799)
 14 2.04±2.09 (0.0803±0.0823)
 15 2.10±2.15 (0.0827±0.0846)
(b) Using a snap ring expander, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10±0.25 mm (0.0039±0.0098 in.)
5. INSTALL 2ND GEAR AND NO.1 CLUTCH HUB
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Install the needle roller bearing in the 2nd gear.
(d) Using a press, install the 2nd gear and No.1 clutch hub.
6. INSPECT 2ND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust clear-
ance.
Standard clearance:
0.10±0.25 mm (0.0039±0.0098 in.)
7. INSTALL LOCKING BALL AND 1ST GEAR ASSEMBLY
(a) Install the locking ball in the shaft.
(b) Apply gear oil to the bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller
bearing and bearing inner race. MT1±32
± W58 MANUAL TRANSMISSIONOUTPUT SHAFT

(d) Install the assembly on the output shaft with the synchronizer
ring slots aligned with the shifting keys and turn the inner race
to align it with the locking ball.
8. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a press, install the bearing on the output shaft
with the outer race snap ring groove toward the rear.
HINT: Hold the 1st gear inner race to prevent it from falling.
SST 09506±35010
9. INSPECT 1ST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:
0.10±0.25 mm (0.0039±0.0098 in.)
± W58 MANUAL TRANSMISSIONOUTPUT SHAFTMT1±33

COUNTER GEAR AND REVERSE
IDLER GEAR
COMPONENTS
COUNTER GEAR COMPONENT PARTS
DISASSEMBLY
REMOVE NO.3 HUB SLEEVE, SHIFTING KEYS AND
SPRINGS FROM SYNCHRONIZER RING
(a) Remove the synchronizer ring assembly from the No.3 hub
sleeve.
(b) Turn the reverse synchronizer pull ring. MT1±34
± W58 MANUAL TRANSMISSIONCOUNTER GEAR AND REVERSE IDLER GEAR