Input Shaft: Inspection

INSPECT INPUT SHAFT

Using a V-block and dial indicator, measure the shaft for runout.
Maximum runout:

0.03 mm (0.0012 in.)

If the runout is greater than the maximum, replace the input shaft.

Fig 1: Measuring Input Shaft Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard outside diameter

STANDARD OUTSIDE DIAMETER SPECIFICATIONS

Journal Position	Outside Diameter
A	35.984 to 36.000 mm (1.4167 to 1.4173 in.)
B	35.984 to 36.000 mm (1.4167 to 1.4173 in.)
C	27.957 to 27.972 mm (1.1007 to 1.1013 in.)

Fig 2: Measuring Outside Diameter Of Input Shaft Journal Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Minimum outside diameter

MINIMUM OUTSIDE DIAMETER SPECIFICATIONS

Journal Position	Outside Diameter
A	35.984 mm (1.4167 In.)
B	35.984 mm (1.4167 In.)
C	27.957 mm (1.1007 in.)

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

INSPECT 4TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
  Standard Inside Diameter:
  
  42.009 to 42.025 mm (1.6539 to 1.6545 in.)
  
  Maximum Inside Diameter:
  
  42.025 mm (1.6545 in.)
  
  If the inside diameter is greater than the maximum, replace the 4th gear.
  
  Fig 3: Measuring Inside Diameter Of 4th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR
1. Using a cylinder gauge, measure the inside diameter.
  Standard inside diameter:
  
  43.009 to 43.025 mm (1.6933 to 1.6939 in.)
  
  Maximum inside diameter:
  
  43.025 mm (1.6939 in.)
  
  If the inside diameter is greater than the maximum, replace the 3rd gear.
  
  Fig 4: Measuring Inside Diameter Of 3rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND SYNCHRONIZER OUTER RING
1. Coat the 4th gear cone with gear oil. Turn the 2nd synchronizer outer ring (synchronizer ring No. 4) in one direction while pushing it against the 4th gear cone. Check that the ring locks.
  If the 2nd synchronizer outer ring does not lock, replace the ring or the 4th gear.
  
  Fig 5: Inspecting 2nd Synchronizer Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the 2nd synchronizer outer ring (No. 4 synchronizer ring) back and 4th gear spline end.
  Standard clearance:
  
  0.75 to 1.65 mm (0.0295 to 0.0650 in.)
  
  If the clearance is out of specification, replace the 2nd synchronizer outer ring.
  
  Fig 6: Measuring Clearance Between 2nd Synchronizer Outer Ring (No. 4 Synchronizer Ring) Back And 4th Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 SYNCHRONIZER RING
1. Coat the 3rd gear cone with gear oil. Turn the No. 3 synchronizer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks. If the No. 3 synchronizer ring does not lock, replace the ring or the 3rd gear.
  
  Fig 7: Inspecting No. 3 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring back and 3rd gear spline end.
  Standard clearance:
  
  0.65 to 1.75 mm (0.0256 to 0.0689 in.)
  
  If the clearance is out of specification, replace the No. 3 synchronizer ring.
  
  Fig 8: Measuring Clearance Between No. 3 Synchronizer Ring Back And 3Rd Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 TRANSMISSION HUB SLEEVE
1. Inspect the sliding condition between the No. 2 transmission hub sleeve and No. 2 transmission clutch hub.
2. Inspect the tip of the spline gear on the No. 2 transmission hub sleeve for wear.
  If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.
  
  Fig 9: Inspecting No. 2 Transmission Hub Sleeve
  Courtesy 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. 2 gear shift fork (B), and calculate the clearance.
  Standard clearance:
  
  A - B = 0.11 to 0.69 mm
  
  If the clearance is out of specification, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork with new ones.
  
  Fig 10: Measuring Width Of No. 2 Transmission Hub Sleeve Groove Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002