Manual Transaxle Unit: Inspection

INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
1. Using a caliper gauge, measure the inside diameter of the reverse idler gear.
  Standard inside diameter: 20.056 to 20.074 mm (0.7896 to 0.7903 in.)
  
  Maximum inside diameter: 20.074 (0.7903 in.)
  
  If the inside diameter is greater than the maximum, replace the reverse idler gear.
  
  Fig 1: Measuring Inside Diameter Of Reverse Idler Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the diameter of the reverse idler gear shaft.
  Standard diameter: 19.984 to 20.000 mm (0.7868 to 0.7874 in.)
  
  Minimum diameter: 19.984 mm (0.7868 in.)
  
  If the diameter is less than the minimum, replace the reverse idler gear shaft.
  
  Fig 2: Measuring Outside Diameter Of Reverse Idler Gear Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 TRANSAXLE CLUTCH HUB
1. Inspect the sliding condition between the No. 3 transaxle clutch hub and the No. 3 transaxle hub sleeve.
2. Inspect the tip of the spline gear on the No. 3 transaxle hub sleeve for wear.
  
  Fig 3: Inspecting Sliding Condition Between No. 3 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 TRANSAXLE HUB SLEEVE
1. Using vernier calipers, measure the width of the No. 3 transaxle hub sleeve groove (A) and the thickness of the claw part on the No. 3 gear shift fork (B), and calculate the clearance.
  Standard clearance: A - B = 0.15 to 0.35 mm (0.0059 to 0.0138 in.)
  
  If the clearance is out of the specification, replace the No. 3 transaxle hub sleeve and No. 3 gear shift fork with new ones.
  
  Fig 4: Measuring Width Of No. 3 Transmission Hub Sleeve Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR
1. Using a caliper gauge, measure the inside diameter of the 5th gear.
  Standard inside diameter: 34.981 to 34.997 mm (1.3772 to 1.3778 in.)
  
  Maximum inside diameter: 34.997 mm (1.3778 in.)
  
  If the inside diameter is greater the maximum, replace the 5th gear.
  
  Fig 5: Measuring Inside Diameter Of 5Th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002