Manual Transaxle Unit: Inspection

INSPECT 5TH GEAR THRUST CLEARANCE

Using a dial indicator, measure the 5th gear thrust clearance.

5th gear thrust clearance

THRUST CLEARANCE REFERENCE

Standard clearance: mm (In.)	Maximum clearance: mm (In.)
0.10 to 0.57 (0.0039 to 0.0224)	0.57 (0.0224)

Fig 1: Inspecting 5Th Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 5th gear radial clearance.

5th gear radial clearance

GEAR RADIAL CLEARANCE REFERENCE

Standard clearance: mm (In.)	Maximum clearance: mm (In.)
KOYO made: 0.015 to 0.058 (0.0006 to 0.0023)	KOYO made: 0.058 (0.0023)
NSK made: 0.015 to 0.056 (0.0006 to 0.0022)	NSK made: 0.056 (0.0022)

If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.

Fig 2: Measuring 5Th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT SYNCHRONIZER RING NO. 3
1. Check for wear or damage.
2. Coat the 5th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks. If the synchronizer ring does not lock, replace the ring or the 5th gear.
  
  Fig 3: Inspecting Synchronizer Ring No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
  Minimum clearance: 0.75 mm (0.0295 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring and gear.
  
  Fig 4: Measuring Shift Fork Lock Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSMISSION HUB SLEEVE NO. 3
1. Check the sliding condition between the transmission hub sleeve No. 3 and transmission clutch hub No. 3.
2. Check that the tip of the spline gear of the transmission hub sleeve No. 3 is not worn down.
  
  Fig 5: Inspecting Transmission Hub Sleeve No.3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the width of the transmission hub sleeve No. 3 groove (A) and the thickness of the claw part on the gear shift fork No. 3 (B), and calculate the clearance.
  Standard clearance (A - B): 0.3 to 0.5 mm (0.012 to 0.0197 in.)
  
  If the clearance is out of specification, replace the transmission hub sleeve No. 3 and gear shift fork No. 3.
  
  Fig 6: Measuring Width Of Transmission Hub Sleeve No. 3 Groove A
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR

Using a caliper gauge, inspect the 5th gear as shown in the illustration.

5th gear inner diameter

GEAR INNER DIAMETER REFERENCE

Standard Inner diameter: mm (In.)	Maximum Inner diameter: mm (In.)
29.915 to 29.931 (1.1778 to 1.1784)	29.931 (1.1784)

Fig 7: Checking 5Th Gear Inner Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the inner diameter exceeds the maximum, replace the 5th gear.

INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

Using a caliper gauge, inspect the reverse idler gear sub-assembly as shown in the illustration.

Reverse idler gear sub-assembly inner diameter:

IDLER GEAR SPECIFICATION

Standard Inner diameter: mm (In.)	Maximum Inner diameter: mm (In.)
18.040 to 18.058 (0.7102 to 0.7109)	18.058(0.7109)

If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assembly.

Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.

Reverse idler gear shaft outer diameter

IDLER GEAR SPECIFICATION

Standard outer diameter: mm (In.)	Minimum outer diameter: mm (in.)
17.966 to 17.984 (0.7073 to 0.7080)	17.966(0.7073)

If the outer diameter is less than the minimum, replace the reverse idler gear shaft.

Fig 8: Measuring Reverse Idler Gear Sub-Assembly