Transfer Assembly: Inspection

1. INSPECT TRANSFER INPUT SHAFT 
   1. Using a micrometer, measure the outer diameter of the input shaft journal surface.

      Minimum diameter: 47.59 mm (1.8736 in.) 

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

      Fig 1: Measuring Outer Diameter Of Input Shaft Journal Surface Using Micrometer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a dial indicator, measure the inside diameter of the input shaft bushing.

   Maximum diameter: 39.14 mm (1.5409 in.) 

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

   Fig 2: Measuring Inside Diameter Of Input Shaft Bushing Using Dial Indicator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSPECT SYNCHRONIZER RING 
   1. Turn the ring and confirm that the input shaft and synchronizer ring are engaged with each other.
      Fig 3: Confirming Input Shaft & Synchronizer Ring Are Engaged

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a feeler gauge, measure the clearance between the synchronizer ring and the input shaft spline.

   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.

   Fig 4: Measuring Clearance Between Synchronizer Ring & Input Shaft Spline Using Feeler Gauge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE 
   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.

   Fig 5: Measuring Thrust Clearance Of Planetary Pinion Gear Using Feeler Gauge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE 
   1. Using a dial indicator, measure the radial clearance of the planetary pinion gear.

   Standard clearance: 0.009 to 0.038 mm (0.0004 to 00015 in.) 

   Maximum clearance: 0.038 mm (0.0015 in.) 

   If the clearance exceeds the maximum, replace the planetary gear assembly.

   Fig 6: Measuring Radial Clearance Of Planetary Pinion Gear Using Dial Indicator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSPECT TRANSFER REAR OUTPUT SHAFT 
   1. Using a micrometer, measure the outer diameter of the output shaft rear journal surface.

   Minimum diameter: 

   • 27.98 mm (1.1016 in.) for part A 
   • 36.98 mm (1.4561 in.) for part B 

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

   Fig 7: Measuring Outer Diameter Of Output Shaft Rear Journal Surface Using Micrometer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSPECT DRIVE SPROCKET RADIAL CLEARANCE 
   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 (0.0004 to 0.0022 in.) 

   Maximum clearance: 0.055 mm (0.0022 in.) 

   If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft and drive sprocket bearing.

   Fig 8: Measuring Radial Clearance Between Sprocket & Shaft Using Dial Indicator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSPECT GEAR SHIFT FORK NO. 1 AND HUB SLEEVE CLEARANCE 
   1. Using a feeler gauge, measure the clearance between the gear shift fork No. 1 and drive clutch sleeve.

   Maximum clearance: 1.0 mm (0.039 in.) 

   If the clearance exceeds the maximum, replace the gear shift fork No. 1 and drive clutch sleeve.

   Fig 9: Measuring Clearance Between Gear Shift Fork & Drive Clutch Sleeve Using Feeler Gauge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSPECT GEAR SHIFT FORK NO. 2 AND HUB SLEEVE CLEARANCE 

1. Using a feeler gauge, measure the clearance between the gear shift fork No. 2 and high and low clutch sleeve.

Maximum clearance: 1.0 mm (0.039 in.) 

If the clearance exceeds the maximum, replace the gear shift fork No. 2 and high and low clutch sleeve.

Fig 10: Measuring Clearance Between Gear Shift Fork No. 2 And High & Low Clutch Sleeve Using Feeler Gauge

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002