Output Shaft: Inspection

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT OUTPUT SHAFT
1. Using a dial gauge and 2 V-blocks, check the output shaft runout.
  Maximum runout:
  
  0.015 mm (0.0006 in.)
  
  If the runout exceeds the maximum, replace the output shaft.
  
  Fig 1: Checking Output Shaft Runout Using Dial Gauge & V-Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the outer diameter of the output shaft journal surface, at the locations indicated.
  Standard outer diameter:
  
  Part A:
  
  31.985 to 32.000 mm (1.2592 to 1.2598 in.)
  
  Part B:
  
  37.985 to 38.000 mm (1.4955 to 1.4961 in.)
  
  Part C:
  
  32.985 to 33.000 mm (1.2986 to 1.2992 in.)
  
  If the outer diameters are less than the minimums, replace the output shaft.
  
  Fig 2: Measuring Outer Diameter Of Output Shaft Journal Surface Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND GEAR
1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.
  Standard inside diameter:
  
  38.015 to 38.031 mm (1.4967 to 1.4972 in.)
  
  Maximum inside diameter:
  
  38.031 mm (1.4972 in.)
  
  If the inside diameter exceeds the maximum, replace the 1st gear.
  
  Fig 3: Measuring Inside Diameter Of 2nd Gear Using Cylinder Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1ST GEAR
1. Using a cylinder gauge, measure the inside diameter of the 1st gear.
  Standard inside diameter:
  
  44.015 to 44.031 mm (1.7328 to 1.7335 in.)
  
  Maximum inside diameter:
  
  44.031 mm (1.7335 in.)
  
  If the inside diameter exceeds the maximum, replace the 1st gear.
  
  Fig 4: Measuring Inside Diameter Of 2nd Gear Using Cylinder Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1 ST GEAR THRUST WASHER
1. Using a micrometer, measure the 1st gear thrust washer.
  Standard thickness:
  
  5.975 to 6.025 mm (0.2352 to 0.2372 in.)
  
  Minimum thickness:
  
  5.975 mm (0.2352 in.)
  
  If the thickness is less than the minimum, replace the 1st gear thrust washer.
  
  Fig 5: Measuring 1st Gear Thrust Washer Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SYNCHRONIZER RING NO.1 (FOR 2ND GEAR)
1. Check for wear and damage.
2. Coat the 2nd gear cone with gear oil.
3. Turn the synchronizer ring in one direction while pushing it against the 2nd gear cone.
4. Check that the ring locks.
  If the synchronizer ring does not lock, replace the synchronizer ring.
  
  Fig 6: Identifying Synchronizer Ring No. 1 (2nd Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end.
  Standard clearance:
  
  0.70 to 1.3 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 7: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SYNCHRONIZER RING NO.1 (FOR 1ST GEAR)
1. Check for wear and damage.
2. Coat the 1st gear cone with gear oil.
3. Turn the synchronizer ring in one direction while pushing it against the 1st gear cone.
4. Check that the ring locks.
  If the synchronizer ring does not lock, replace the synchronizer ring.
  
  Fig 8: Identifying 4th Gear Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end.
  Standard clearance:
  
  0.75 to 1.65 mm (0.0295 to 0.0650 in.)
  
  Minimum clearance:
  
  0.75 mm (0.0295 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring.
  
  Fig 9: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE GEAR
1. Using a 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 outside the specifications, replace the reverse gear and reverse shift fork.
  
  Fig 10: Measuring Width Of Reverse Gear Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSMISSION CLUTCH HUB NO.1
1. Check that transmission clutch hub No. 1 and the reverse gear slide smoothly.
2. Check that the edges of the reverse gear spline gear are not worn down.
  
  Fig 11: Checking Transmission Clutch Hub No. 1 & Reverse Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002