Output Shaft: Inspection

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

INSPECT 1ST GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 1st gear thrust clearance.
  Standard clearance: 0.10 to 0.40 mm (0.0039 to 0.0157 in.)
  
  Fig 1: Measuring 1st Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 2nd gear thrust clearance.
  Standard clearance: 0.10 to 0.45 mm (0.0039 to 0.0177 in.)
  
  Fig 2: Measuring 2nd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 1ST GEAR RADIAL CLEARANCE

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

Standard clearance

BEARING CLEARANCE SPECIFICATION CHART

Bearing	Clearance: mm (in.)
KOYO made	0.015 to 0.058 (0.0006 to 0.0023)
NSK made	0.015 to 0.056 (0.0006 to 0.0022)

If the clearance is out of specification, replace the 1st gear needle roller bearing.

Fig 3: Measuring 1st Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2ND GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 2nd gear radial clearance.

Standard clearance

BEARING CLEARANCE SPECIFICATION CHART

Bearing	Clearance: mm (in.)
KOYO made	0.015 to 0.058 (0.0006 to 0.0023)
NSK made	0.015 to 0.056 (0.0006 to 0.0022)

If the clearance is out of specification, replace the 2nd gear needle roller bearing.

Fig 4: Measuring 2nd Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT OUTPUT SHAFT
1. Using a dial indicator and 2 V-blocks, measure the shaft runout.
  Maximum runout: 0.015 mm (0.0006 in.)
  
  If the runout exceeds the maximum, replace the output shaft.
  
  Fig 5: Measuring Output Shaft Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the outer diameter of the output shaft journal surface.
  Outer diameter:
  
  Part A: 31.985 mm (1.2592 in.)
  
  Part B: 37.985 mm (1.4955 in.)
  
  Part C: 32.985 mm (1.2986 in.)
  
  If the outer diameter is below the minimum, replace the output shaft.
  
  Fig 6: Measuring Outer Diameter Of Output Shaft Journal Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2ND GEAR

Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Inside diameter

2ND GEAR DIAMETER SPECIFICATION CHART

New gear: mm (in.)	Maximum Inside diameter: mm (in.)
30.015 to 38.031 (1.4967 to 1.4973)	38.031 (1.4973)

If the inside diameter exceeds the maximum, replace the 2nd gear.

Fig 7: Measuring Inside Diameter Of 2nd Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 1ST GEAR

Using a cylinder gauge, measure the inside diameter of the 1st gear.

Inside diameter

1ST GEAR INSIDE DIAMETER SPECIFICATION CHART

New gear: mm (in.)	Maximum inside diameter: mm (in.)
44.015 to 44.031 (1.7329 to 1.7335)	44.031 (1.7335)

If the inside diameter exceeds the maximum, replace the 1st gear.

Fig 8: Measuring Inside Diameter Of 1st Gear

INSPECT 1ST GEAR THRUST WASHER

Using a micrometer, measure the thickness of 1st gear thrust washer.

Thickness

THICKNESS SPECIFICATION CHART

New thrust washer: mm (in.)	Minimum thickness: mm (in.)
5.975 to 6.025 (0.2352 to 0.2372)	5.975 (0.2352)

If the thickness is below the minimum, replace the 1st gear thrust washer.

Fig 9: Measuring Thickness Of 1st Gear Thrust Washer

INSPECT SYNCHRONIZER RING SET NO. 2
1. Coat the 2nd gear cone with gear oil.
  Turn the synchronizer ring in one direction while pushing it against the 2nd gear cone. Check that the ring locks.
  
  If the synchronizer ring does not lock, replace the ring or 2nd gear.
  
  Fig 10: Turning Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
  Standard clearance: 0.7 to 1.3 mm (0.0276 to 0.0512 in.)
  
  If the clearance is out of specification, replace the synchronizer ring set No. 2.
  
  Fig 11: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SYNCHRONIZER RING NO. 1
1. Coat the 1st gear cone with gear oil.
  Turn the synchronizer ring in one direction while pushing it against the 1st gear cone. Check that the ring locks.
  
  If the synchronizer ring does not lock, replace the ring or 1st gear.
  
  Fig 12: Inspecting Synchronizer Ring No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
  Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.065)
  
  If the clearance is out of specification, replace the synchronizer ring No. 1.
  
  Fig 13: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE GEAR
1. Using vernier calipers, measure the width of the reverse gear groove (A) and the thickness of the claw part on the reverse 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 out of specification, replace the reverse gear and reverse shift fork.
  
  Fig 14: Measuring Width Of Reverse Gear Groove (A) And Thickness Of Claw Part
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSMISSION CLUTCH HUB NO. 1
1. Check that the transmission clutch hub No. 1 and reverse gear sub-assembly slides smoothly.
2. Check that the spline gear's edges of the reverse gear sub-assembly is not worn down.