LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2024 >> Corolla LE >> Repair and Diagnosis >> External Pages >> Different car >> Section 319 (Manual Transaxle System - Service Information (2 Of 2)) >> Output Shaft >> Inspection [09/2022 - ] >> Procedure

Inspection [09/2022 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota GR Corolla, 2024 Toyota GR Corolla, and 2023 Toyota GR Corolla. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSPECT NO. 1 OUTPUT SHAFT 
    1. Check the No. 1 output shaft for wear and damage.
    2. Using a dial indicator, check the No. 1 output shaft runout.
      GTY1021651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum Runout

      0.01 mm (0.000394 in.)

      If the runout exceeds the maximum, replace the No. 1 output shaft.

    3. Using a micrometer, measure the outer diameter of the No. 1 output shaft journal surface.
      GTY1021938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard

      Measured Part Outer Diameter mm (in.)
      A 32.002 to 32.018 (1.2599 to 1.2605)
      B 35.984 to 36.000 (1.4167 to 1.4173)
      C 41.984 to 42.000 (1.6529 to 1.6535)
      D 41.989 to 42.000 (1.6531 to 1.6535)
      E 46.984 to 47.000 (1.8498 to 1.8504)
      F 36.002 to 36.018 (1.4174 to 1.4180)

      If the outer diameter is below the minimum, replace the No. 1 output shaft.

  2. INSPECT 1ST DRIVEN GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 1st driven gear.
      GTY1021519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      53.015 to 53.040 mm (2.0872 to 2.0882 in.)

      Maximum Inside Diameter

      53.040 mm (2.0882 in.)

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

  3. INSPECT 2ND DRIVEN GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 2nd driven gear.
      GTY1021517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      56.015 to 56.030 mm (2.2053 to 2.2059 in.)

      Maximum Inside Diameter

      56.030 mm (2.2059 in.)

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

  4. INSPECT 3RD DRIVEN GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 3rd driven gear.
      GTY1021506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      42.015 to 42.040 mm (1.6541 to 1.6551 in.)

      Maximum Inside Diameter

      42.040 mm (1.6551 in.)

      If the inside diameter exceeds the maximum, replace the 3rd driven gear.

  5. INSPECT 4TH DRIVEN GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 4th driven gear.
      GTY1021505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      48.015 to 48.040 mm (1.8904 to 1.8913 in.)

      Maximum Inside Diameter

      48.040 mm (1.8913 in.)

      If the inside diameter exceeds the maximum, replace the 4th driven gear.

  6. INSPECT 1ST DRIVEN GEAR SYNCHRONIZER RING SET 
    1. Coat the 1st driven gear synchronizer ring set with gear oil.
    2. Install the inner ring to the 1st driven gear.
      GTY1021884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inner Ring
    3. Install the middle ring to the 1st driven gear.
      GTY1022121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Middle Ring
    4. Install the outer ring to the 1st driven gear.
      GTY1021648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Outer Ring
    5. Coat the 1st driven gear with gear oil.
    6. Check that the 1st driven gear synchronizer ring set does not turn when the 1st driven gear synchronizer ring set is pushed to the 1st driven gear.
      GTY1022146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a feeler gauge, measure the clearance between the 1st driven gear synchronizer ring set back and the gear spline end.
      GTY1021511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.98 to 1.82 mm (0.0386 to 0.0717 in.)

      Minimum Clearance

      0.98 mm (0.0386 in.)

      If the clearance is below the minimum, replace the 1st driven gear synchronizer ring set.

  7. INSPECT 2ND DRIVEN GEAR SYNCHRONIZER RING SET 
    1. Coat the 2nd driven gear synchronizer ring set with gear oil.
    2. Install the inner ring to the 2nd driven gear.
      GTY1022205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inner Ring
    3. Install the middle ring to the 2nd driven gear.
      GTY1022528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Middle Ring
    4. Install the outer ring to the 2nd driven gear.
      GTY1021497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Outer Ring
    5. Coat the 2nd driven gear with gear oil.
    6. Check that the 2nd driven gear synchronizer ring set does not turn when the 2nd driven gear synchronizer ring set is pushed to the 2nd driven gear.
      GTY1022151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a feeler gauge, measure the clearance between the 2nd driven gear synchronizer ring set back and the gear spline end.
      GTY1021514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      1.28 to 2.12 mm (0.0504 to 0.0835 in.)

      Minimum Clearance

      1.28 mm (0.0504 in.)

      If the clearance is below the minimum, replace the 2nd driven gear synchronizer ring set.

  8. INSPECT 3RD DRIVEN GEAR SYNCHRONIZER RING SET 
    1. Coat the 3rd driven gear synchronizer ring set with gear oil.
    2. Install the inner ring to the 3rd driven gear.
      GTY1022434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inner Ring
    3. Install the middle ring to the 3rd driven gear.
      GTY1021927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Middle Ring
    4. Install the outer ring to the 3rd driven gear.
      GTY1021340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Outer Ring
    5. Coat the 3rd driven gear with gear oil.
    6. Check that the 3rd driven gear synchronizer ring set does not turn when the 3rd driven gear synchronizer ring set is pushed to the 3rd driven gear.
      GTY1022148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a feeler gauge, measure the clearance between the 3rd driven gear synchronizer ring set back and the gear spline end.
      GTY1022160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      1.00 to 2.00 mm (0.0394 to 0.0787 in.)

      Minimum Clearance

      1.00 mm (0.0394 in.)

      If the clearance is below the minimum, replace the 3rd driven gear synchronizer ring set.

  9. INSPECT 4TH DRIVEN GEAR SYNCHRONIZER RING SET 
    1. Coat the 4th driven gear synchronizer ring set with gear oil.
    2. Install the inner ring to the 4th driven gear.
      GTY1021949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inner Ring
    3. Install the middle ring to the 4th driven gear.
      GTY1021819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Middle Ring
    4. Install the outer ring to the 4th driven gear.
      GTY1022368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Outer Ring
    5. Coat the 4th driven gear with gear oil.
    6. Check that the 4th driven gear synchronizer ring set does not turn when the 4th driven gear synchronizer ring set is pushed to the 4th driven gear.
      GTY1022153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a feeler gauge, measure the clearance between the 4th driven gear synchronizer ring set back and the gear spline end.
      GTY1022158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.92 to 1.88 mm (0.0362 to 0.074 in.)

      Minimum Clearance

      0.92 mm (0.0362 in.)

      If the clearance is below the minimum, replace the 4th driven gear synchronizer ring set.

  10. INSPECT NO. 1 TRANSMISSION HUB SLEEVE 
    1. Using a vernier caliper, measure the clearance between the No. 1 transmission hub sleeve and the No. 1 gear shift fork.
      GTY1024023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance (A - B)

      0.10 to 0.50 mm (0.00394 to 0.0197 in.)

      If the clearance is outside the specifications, replace the No. 1 transmission hub sleeve and No. 1 gear shift fork.

  11. INSPECT NO. 2 TRANSMISSION HUB SLEEVE 
    1. Using a vernier caliper, measure the clearance between the No. 2 transmission hub sleeve and the No. 2 gear shift fork.
      GTY1024243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance (A - B)

      0.35 to 0.75 mm (0.0138 to 0.0295 in.)

      If the clearance is outside the specifications, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork.

  12. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 1st driven gear thrust clearance.
      GTY1022306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.10 to 0.35 mm (0.00394 to 0.0138 in.)

      Maximum Clearance

      0.35 mm (0.0138 in.)

      If the clearance exceeds the maximum, replace the 1st driven gear, needle roller bearing or No. 1 output shaft.

  13. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 1st driven gear radial clearance.
      GTY1022303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.015 to 0.068 mm (0.000591 to 0.00268 in.)

      Maximum Clearance

      0.068 mm (0.00268 in.)

      If the clearance exceeds the maximum, replace the 1st driven gear, needle roller bearing or No. 1 output shaft.

  14. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 2nd driven gear thrust clearance.
      GTY1022302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.11 to 0.46 mm (0.00433 to 0.0181 in.)

      Maximum Clearance

      0.46 mm (0.0181 in.)

      If the clearance exceeds the maximum, replace the 2nd driven gear, needle roller bearing or No. 1 output shaft.

  15. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 2nd driven gear radial clearance.
      GTY1021859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.015 to 0.048 mm (0.000591 to 0.00189 in.)

      Maximum Clearance

      0.048 mm (0.00189 in.)

      If the clearance exceeds the maximum, replace the 2nd driven gear, needle roller bearing or No. 1 output shaft.

  16. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 3rd driven gear thrust clearance.
      GTY1022140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.11 to 0.54 mm (0.00433 to 0.0213 in.)

      Maximum Clearance

      0.54 mm (0.0213 in.)

      If the clearance exceeds the maximum, replace the 3rd driven gear, needle roller bearing or No. 1 output shaft.

  17. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 3rd driven gear radial clearance.
      GTY1022564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.015 to 0.066 mm (0.000591 to 0.0026 in.)

      Maximum Clearance

      0.066 mm (0.0026 in.)

      If the clearance exceeds the maximum, replace the 3rd driven gear, needle roller bearing or No. 1 output shaft.

  18. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 4th driven gear thrust clearance.
      GTY1022210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.10 to 0.65 mm (0.00394 to 0.0256 in.)

      Maximum Clearance

      0.65 mm (0.0256 in.)

      If the clearance exceeds the maximum, replace the 4th driven gear, needle roller bearing or No. 1 output shaft.

  19. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 4th driven gear radial clearance.
      GTY1022212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.015 to 0.066 mm (0.000591 to 0.0026 in.)

      Maximum Clearance

      0.066 mm (0.0026 in.)

      If the clearance exceeds the maximum, replace the 4th driven gear, needle roller bearing or No. 1 output shaft.

scientia non olet · About LEMON Manuals