Output Shaft: Inspection: Inspection

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

INSPECT OUTPUT SHAFT
1. Using a dial indicator and 2 V-blocks, check the output shaft runout.
  
  Fig 1: Checking Output Shaft Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum runout
  
  0.015 mm (0.000591 in.)
  
  If the runout exceeds the maximum, replace the output shaft.
2. Using a micrometer, measure the outer diameter of the output shaft journal surface at the locations indicated.
  
  Fig 2: Measuring Outer Diameter Of Output Shaft Journal Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 any of the outer diameters are less than the minimum, replace the output shaft.
INSPECT 2ND GEAR
1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.
  
  Fig 3: Measuring Inside Diameter Of 2nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT 1ST GEAR
1. Using a cylinder gauge, measure the inside diameter of the 1st gear.
  
  Fig 4: Measuring Inside Diameter Of 2nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT 1ST GEAR THRUST WASHER
1. Using a micrometer, measure the 1st gear thrust washer.
  
  Fig 5: Measuring 1st Gear Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSPECT NO. 2 SYNCHRONIZER RING SET (FOR 2ND GEAR)
1. Coat the 2nd gear cone and No. 2 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
  
  Fig 6: Identifying 2nd Gear Cone And No. 2 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the inner ring onto the 2nd gear.
3. Install the middle ring onto the 2nd gear.
  
  Fig 7: Identifying Middle Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the outer ring onto the 2nd gear.
  
  Fig 8: Identifying Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check for wear and damage.
  
  Fig 9: Checking Ring Set Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.
7. Check that the ring set locks.
  If the synchronizer ring set does not lock, replace the synchronizer ring set.
8. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.
  
  Fig 10: Measuring Clearance Between Synchronizer Ring And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard clearance
  
  0.60 to 1.40 mm (0.0236 to 0.0551 in.)
  
  Minimum clearance
  
  0.60 mm (0.0236 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring set.
INSPECT NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)
1. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
  
  Fig 11: Identifying 1st Gear Cone And No. 1 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the inner ring onto the 1st gear.
3. Install the middle ring onto the 1st gear.
  
  Fig 12: Identifying Middle Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the outer ring onto the 1st gear.
  
  Fig 13: Identifying Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check for wear and damage.
  
  Fig 14: View Of Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Turn the synchronizer ring set in one direction while pushing it against the 1st gear cone.
7. Check that the ring set locks.
  If the synchronizer ring set does not lock, replace the synchronizer ring set.
8. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.
  
  Fig 15: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard clearance
  
  0.60 to 1.40 mm (0.0236 to 0.0551 in.)
  
  Minimum clearance
  
  0.60 mm (0.0236 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring set.
INSPECT REVERSE GEAR
1. Using a vernier caliper, 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.
  
  Fig 16: Measuring Width Of Reverse Gear Groove (A) And Thickness Of Claw Part On Reverse Shift Fork (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard clearance (A - B)
  
  0.15 to 0.35 mm (0.00591 to 0.0138 in.)
  
  If the clearance is out of specification, replace the reverse gear and reverse shift fork.
INSPECT NO. 1 TRANSMISSION CLUTCH HUB
1. Check that the No. 1 transmission clutch hub and reverse gear slide smoothly.
  
  Fig 17: Checking Transmission Clutch Hub No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the edges of the reverse gear spline gear are not worn down.