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Input Shaft: Inspection

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  1. INSPECT INPUT SHAFT 
    1. Using a dial indicator and 2 V-blocks, measure the shaft runout.

      Maximum runout: 0.03 mm (0.0012 in.) 

      If the runout exceeds the maximum, replace the input shaft.

      Fig 1: Measuring Shaft Runout Using Dial Indicator & V-Blocks
      G04046580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a micrometer, measure the outer diameter of the input shaft journal surface.

      Standard 

      MEASUREMENT SPECIFICATION (STANDARD)

      Part Outer diameter mm (in.)
      A 34.002 to 34.015 (1.3387 to 1.3392)
      B 44.985 to 45.000 (1.7711 to 1.7717)
      C 44.985 to 45.000 (1.7711 to 1.7717)
      D 41.985 to 42.000 (1.6530 to 1.6535)
      E 32.967 to 32.980 (1.2979 to 1.2984)

      Minimum 

      MEASUREMENT SPECIFICATION (MINIMUM)

      Part Outer diameter mm (in.)
      A 34.002 (1.3387)
      B 44.985 (1.7711)
      C 44.985 (1.7711)
      D 41.985 (1.6530)
      E 32.967 (1.2979)

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

      Fig 2: Measuring Outer Diameter Of Input Shaft Journal Surface Using Micrometer
      G04046581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT 6TH GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 6th gear.

      Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 in.) 

      Maximum inside diameter: 51.040 mm (2.0095 in.) 

      If the inside diameter exceeds the maximum, replace the 6th gear.

      Fig 3: Measuring Inside Diameter Of 6th Gear Using Cylinder Gauge
      G04046582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT 3RD GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.

      Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 in.) 

      Maximum inside diameter: 51.040 mm (2.0095 in.) 

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

      Fig 4: Measuring Inside Diameter Of 3rd Gear Using Cylinder Gauge
      G04046583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT 4TH GEAR 
    1. Using a cylinder gauge, measure the inside diameter of the 4th gear.

      Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 in.) 

      Maximum inside diameter: 51.040 mm (2.0095 in.) 

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

      Fig 5: Measuring Inside Diameter Of 4th Gear Using Cylinder Gauge
      G04046584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT NO. 2 TRANSMISSION HUB SLEEVE 
    1. Check the sliding condition between the No. 2 transmission clutch hub and No. 2 transmission hub sleeve.
      Fig 6: Checking Sliding Condition Between No. 2 Clutch Hub & No. 2 Transmission Hub Sleeve
      G04046585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the spline gear teeth of the No. 2 transmission hub sleeve are not worn.

      If there are any defects, replace the No. 2 transmission hub sleeve.

    3. Using vernier calipers, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 2 gear shift forks (B), and calculate the clearance.

      Standard clearance (A - B): 0.28 to 0.66 mm (0.0110 to 0.0260 in.) 

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

      Fig 7: Measuring Width Of No. 2 Transmission Hub Sleeve Groove & Thickness Of Claw Part On No. 2 Gear Shift Forks
      G04046586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT NO. 3 TRANSMISSION HUB SLEEVE 
    1. Check the sliding condition between the No. 3 transmission clutch hub and No. 3 transmission hub sleeve.
    2. Check that the spline gear teeth of the No. 3 transmission hub sleeve are not worn.

      If there are any defects, replace the No. 3 transmission hub sleeve.

      Fig 8: Checking Sliding Condition Between No. 3 Transmission Clutch Hub & No. 3 Transmission Hub Sleeve
      G04046587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using vernier calipers, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 3 and No. 3 gear shift forks (B), and calculate the clearance.

      Standard clearance (A - B): 0.28 to 0.66 mm (0.0110 to 0.0260 in.) 

      If the clearance is outside the specification, replace the No. 3 transmission hub sleeve and gear shift fork.

      Fig 9: Measuring Width Of No. 2 Transmission Hub Sleeve Groove & Thickness Of Claw Part On No. 3 Gear Shift Forks
      G04046588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSPECT NO. 3 SYNCHRONIZER RING (for 6th Gear) 
    1. Using a feeler gauge, measure the clearance between the synchronizer ring and the 6th gear.

      Standard clearance: 0.80 to 1.60 mm (0.0315 to 0.0630 in.) 

      Minimum clearance: 0.80 mm (0.0315 in.) 

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

      Fig 10: Measuring Clearance Between Synchronizer Ring & 6th Gear Using Feeler Gauge
      G04046589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the 6th gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the 6th gear cone. Check that the ring locks.
      Fig 11: Turning Synchronizer Ring In One Direction
      G04046590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT NO. 2 SYNCHRONIZER RING SET 
    1. Using a feeler gauge, measure the clearance between the synchronizer ring and the 3rd gear.

      Standard clearance: 

      • Inner: 1.20 to 2.20 mm (0.0472 to 0.0866 in.) 
      • Middle: 0.60 to 1.80 mm (0.0236 to 0.0709 in.) 
      • Outer: 0.80 to 1.80 mm (0.0315 to 0.0709 in.) 

      Minimum clearance: 

      • Inner: 1.20 mm (0.0472 in.) 
      • Middle: 0.60 mm (0.0236 in.) 
      • Outer: 0.80 mm (0.0315 in.) 

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

      Fig 12: Measuring Clearance Between Synchronizer Ring & 3rd Gear Using Feeler Gauge
      G04046591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the 3rd gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the 3rd gear cone. Check that the ring locks.
      Fig 13: Turning Synchronizer Ring In One Direction
      G04046592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT NO. 3 SYNCHRONIZER RING (for 4th Gear) 
    1. Using a feeler gauge, measure the clearance between the synchronizer ring and 4th gear.

      Standard clearance: 0.80 to 1.60 mm (0.0315 to 0.0630 in.) 

      Minimum clearance: 0.80 mm (0.0315 in.) 

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

      Fig 14: Measuring Clearance Between Synchronizer Ring & 4th Gear
      G04046593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the 4th gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the 4th gear cone. Check that the ring locks.
      Fig 15: Turning Synchronizer Ring In One Direction
      G04046594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT 3RD GEAR THRUST WASHER 
    1. Using a micrometer, measure the thrust washer thickness.

      Standard thickness: 7.12 to 7.18 mm (0.2803 to 0.2827 in.) 

      Minimum thickness: 7.12 mm (0.2803 in.) 

      If the thickness is less than the minimum, replace the thrust washer.

      Fig 16: Measuring Thrust Washer Thickness Using Micrometer
      G04046595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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