Inspection [08/2015 - 08/2019]: Procedure

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

INSPECT TRANSFER INPUT SHAFT

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

47.59 mm (1.88 in.)

If the outer diameter is less than the minimum, replace the input shaft.

Using a dial indicator, measure the inside diameter of the input shaft bushing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Maximum diameter

39.14 mm (1.54 in.)

If the inside diameter exceeds the maximum, replace the input shaft.

INSPECT SYNCHRONIZER RING

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn the ring and confirm that the input shaft and synchronizer ring are engaged with each other.

Using a feeler gauge, measure the clearance between the synchronizer ring and the input shaft spline.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard clearance

1.05 to 1.85 mm (0.0413 to 0.0728 in.)

Minimum clearance

0.80 mm (0.0315 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

INSPECT PLANETARY PINION GEAR THRUST CLEARANCE

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.
  Standard clearance
  
  0.11 to 0.84 mm (0.0043 to 0.0331 in.)
  
  Maximum clearance
  
  0.84 mm (0.0331 in.)
  
  If the clearance exceeds the maximum, replace the planetary gear assembly.
INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a dial indicator, measure the radial clearance of the planetary pinion gear.
  Standard clearance
  
  0.009 to 0.038 mm (0.00035 to 0.00150 in.)
  
  Maximum clearance
  
  0.038 mm (0.00150 in.)
  
  If the clearance exceeds the maximum, replace the planetary gear assembly.
INSPECT TRANSFER REAR OUTPUT SHAFT

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a micrometer, measure the outer diameter of the output shaft rear journal surface.
  Minimum diameter
  
  27.98 mm (1.102 in.) for part A
  
  36.98 mm (1.456 in.) for part B
  
  If the outer diameter is less than the minimum, replace the output shaft rear.
INSPECT DRIVE SPROCKET RADIAL CLEARANCE

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a dial indicator, measure the radial clearance between the sprocket and the shaft with the needle roller bearing installed.
  Standard clearance
  
  0.010 to 0.055 mm (0.00039 to 0.00217 in.)
  
  Maximum clearance
  
  0.055 mm (0.00217 in.)
  
  If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft and drive sprocket bearing.

INSPECT NO. 1 TRANSFER GEAR SHIFT FORK AND FRONT DRIVE CLUTCH SLEEVE CLEARANCE

Using a vernier caliper, measure the thickness of the No. 1 transfer gear shift fork claw.

Standard thickness (A)

11.85 to 11.95 mm (0.467 to 0.47 in.)

Using a vernier caliper, measure the width of the groove of the front drive clutch sleeve.
Standard width (B)

12.0 to 12.1 mm (0.472 to 0.476 in.)
Calculate the clearance between the front drive clutch sleeve and No. 1 transfer gear shift fork.
Standard clearance (B) - (A)

0.05 to 0.25 mm (0.002 to 0.0098 in.)

Maximum clearance (B) - (A)

0.25 mm (0.0098 in.)

If the clearance is more than the maximum, replace the front drive clutch sleeve or No. 1 transfer gear shift fork.

INSPECT NO. 2 TRANSFER GEAR SHIFT FORK AND TRANSFER HIGH AND LOW CLUTCH SLEEVE CLEARANCE

Using a vernier caliper, measure the thickness of the No. 2 transfer gear shift fork claw.

Standard thickness (A)

11.75 to 11.85 mm (0.463 to 0.467 in.)

Using a vernier caliper, measure the width of the groove of the transfer high and low clutch sleeve.
Standard width (B)

12.0 to 12.1 mm (0.472 to 0.476 in.)
Calculate the clearance between the high and low clutch sleeve and No. 2 transfer gear shift fork.
Standard clearance (B) - (A)

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

Maximum clearance (B) - (A)

0.35 mm (0.0138 in.)

If the clearance is more than the maximum, replace the transfer high and low clutch sleeve or No. 2 transfer gear shift fork.