Output Shaft: Inspection

INSPECT GEAR SYNCHRONIZER RINGS
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.
  
  Fig 1: Turning Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If it does not lock, replace the synchronizer ring.
3. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
  
  Fig 2: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Minimum clearance: 0.7 mm (0.028 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring.
MEASURE NO. 1 SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Fig 3: Measuring Clearance Between Hub Sleeve And Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Maximum clearance: 0.35 mm (0.0138 in.)

If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
INSPECT OUTPUT SHAFT
1. Check the output shaft for wear or damage.
2. Using a micrometer, measure the outer diameter of the output shaft journal surface.
  
  Fig 4: Measuring Outer Diameter Of Output Shaft Journal Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Minimum outer diameter:
  
  Part A: 37.610 mm (1.4807 in.)
  
  Part B: 34.502 mm (1.3583 in.)
3. Using a dial indicator, check the shaft runout.
  
  Fig 5: Checking Shaft Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Maximum runout: 0.03 mm (0.0012 in.)