Output Shaft: Inspection

INSPECT NO. 1 SYNCHRONIZER RING
1. Check for wear or damage.
2. Check the braking effect of the synchronizer ring.
  Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
  
  If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
  
  NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
3. Check again the braking effect of the synchronizer ring.
  
  Fig 1: Removing Reverse Gear From No. 1 Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
1. Minimum clearance: 0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.

NOTE: Ensure the fine lapping compound is completely washed off after rubbing.

Fig 2: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 SYNCHRONIZER RING
1. Check for wear or damage.
2. Check the braking effect of the synchronizer ring.
  Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
  
  If the braking effect is insufficient, replace the synchronizer ring.
  
  Fig 3: Checking Braking Effect Of Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
1. Minimum clearance: 0.70 mm (0.0276 in.)
If the clearance is less than the minimum, replace the synchronizer ring.

Fig 4: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 GEAR SHIFT FORK AND REVERSE GEAR CLEARANCE
Using a feeler gauge, measure the clearance between the reverse gear and gear shift fork.
1. Maximum clearance: 0.35 mm (0.014 in.)
If the clearance exceeds the maximum, replace the gear shift fork or reverse gear.

Fig 5: Measuring Clearance Between Reverse Gear And Gear Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OUTPUT SHAFT
1. Check the output shaft for wear or damage.
2. Using a micrometer, measure the journal diameter.
  Minimum journal diameter:
  
  Fig 6: Minimum Journal Diameter Specification Chart
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the journal diameter is less than the minimum, replace the output shaft.
  
  Fig 7: Checking Output Shaft For Wear Or Damage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a dial indicator, check the shaft runout.
  1. Maximum runout: 0.03 mm (0.0012 in.)
If the runout exceeds the maximum, replace the output shaft.

Fig 8: Checking Shaft Runout Using Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002