Counter Gear And Reverse Idler Gear: Inspection

WARNING: This page is about a different variant/trim than selected.

INSPECT COUNTER GEAR

Using a dial indicator and 2 V-blocks, measure the shaft runout.
Maximum runout:

0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the counter gear.

Fig 1: Measuring Shaft Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the outer diameter of the input shaft journal surface.

Standard

OUTER DIAMETER OF INPUT SHAFT JOURNAL SURFACE

Part	Outer diameter mm (in.)
A	34.002 to 34.015 (1.3387 to 1.3392)
B	36.985 to 37.000 (1.4561 to 1.4567)
C	47.985 to 48.000 (1.8892 to 1.8898)
D	53.985 to 54.000 (2.1254 to 2.1260)
E	34.002 to 34.015 (1.3387 to 1.3392)

Minimum

OUTER DIAMETER

Part	Outer diameter mm (in.)
A	34.002 (1.3387)
B	36.985 (1.4561)
C	47.985 (1.8892)
D	53.985 (2.1254)
E	34.002 (1.3387)

If the diameter is less than the minimum, replace the counter gear shaft.

Fig 2: Measuring Outer Diameter Of Input Shaft Journal Surface

INSPECT COUNTER SHAFT REVERSE GEAR
1. Using a cylinder gauge, measure the inside diameter of the reverse gear.
  Standard inside diameter:
  
  51.015 to 51.040 mm (2.0085 to 2.0095 in.)
  
  Maximum inside diameter:
  
  51.040 mm (2.0095 in.)
  
  If the inside diameter exceeds the maximum, replace the reverse gear.
  
  Fig 3: Measuring Inside Diameter Of Reverse Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT COUNTER SHAFT GEAR 1ST SPEED
1. Using a cylinder gauge, measure the inside diameter of the 1st gear.
  Standard inside diameter:
  
  54.015 to 54.040 mm (2.1266 to 2.1276 in.)
  
  Maximum inside diameter:
  
  54.040 mm (2.1276 in.)
  
  If the inside diameter exceeds the maximum, replace the 1st gear.
  
  Fig 4: Measuring Inside Diameter Of 1st Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT COUNTER SHAFT 2ND SPEED GEAR
1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.
  Standard inside diameter:
  
  60.015 to 60.040 mm (2.3628 to 2.3638 in.)
  
  Maximum inside diameter:
  
  60.040 mm (2.3638 in.)
  
  If the inside diameter exceeds the maximum, replace the 2nd gear.
  
  Fig 5: Measuring Inside Diameter Of 2nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 TRANSMISSION HUB SLEEVE
1. Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 4 gear shift fork (B), and calculate the clearance.
  Standard clearance (A - B):
  
  0.26 to 0.84 mm (0.0102 to 0.0331 in.)
  
  If the clearance is outside the specification, replace the No. 3 transmission hub sleeve and No. 4 gear shift fork.
  
  Fig 6: Inspecting No. 3 Transmission Hub Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 TRANSMISSION HUB SLEEVE
1. Check the sliding condition between the No. 1 transmission clutch hub and No. 1 transmission hub sleeve.
2. Check that the spline gear teeth of the No. 1 transmission hub sleeve are not worn.
  
  Fig 7: Checking Sliding Condition Between Transmission Hub Sleeve No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the width of the No. 1 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 1 gear shift fork (B), and calculate the clearance.
  Standard clearance (A - B):
  
  0.15 to 0.35 mm (0.0059 to 0.0138 in.)
  
  If the clearance is outside the specification, replace the No. 1 transmission hub sleeve and No. 1 gear shift fork.
  
  Fig 8: Measuring Width Of No. 1 Transmission Hub Sleeve Groove (A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 4 SYNCHRONIZER RING
1. Using a feeler gauge, measure the clearance between the synchronizer ring and reverse gear.
  Standard clearance:
  
  0.70 to 1.30 mm (0.0276 to 0.0512 in.)
  
  Minimum clearance:
  
  0.70 mm (0.0276 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring.
  
  Fig 9: Measuring Clearance Between Synchronizer Ring And Reverse Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the reverse gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the reverse gear cone. Check that the ring locks.
  
  Fig 10: Turning Synchronizer Ring In One Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 SYNCHRONIZER RING SET (for 1st Gear)
1. Using a feeler gauge, measure the clearance between the synchronizer ring and 1st gear.
  Standard clearance:
  
  Inner:
  
  1.48 to 2.12 mm (0.0583 to 0.0835 in.)
  
  Middle:
  
  0.68 to 1.92 mm (0.0268 to 0.0756 in.)
  
  Outer:
  
  0.88 to 1.72 mm (0.0346 to 0.0677 in.)
  
  Fig 11: Measuring Clearance Between Synchronizer Ring And 1st Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Minimum clearance:
  
  Inner:
  
  1.48 mm (0.0583 in.)
  
  Middle:
  
  0.68 mm (0.0268 in.)
  
  Outer:
  
  0.88 mm (0.0346 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring.
2. Coat the 1st gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the 1st gear cone. Check that the ring locks.
  
  Fig 12: Turning Synchronizer Ring In One Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)
1. Using a feeler gauge, measure the clearance between the synchronizer ring and 2nd gear.
  Standard clearance:
  
  Inner:
  
  1.48 to 2.12 mm (0.0583 to 0.0835 in.)
  
  Middle:
  
  0.68 to 1.92 mm (0.0268 to 0.0756 in.)
  
  Outer:
  
  0.88 to 1.72 mm (0.0346 to 0.0677 in.)
  
  Minimum clearance:
  
  Inner:
  
  1.48 mm (0.0583 in.)
  
  Middle:
  
  0.68 mm (0.0268 in.)
  
  Outer:
  
  0.88 mm (0.0346 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring.
  
  Fig 13: Measuring Clearance Between Synchronizer Ring And 2nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2nd gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the 2nd gear cone. Check that the ring locks.
  
  Fig 14: Turning Synchronizer Ring In One Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002