Output Shaft: Inspection

WARNING: This page is about a different variant/trim than selected.

INSPECT 1ST GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 1st gear thrust clearance.
  Standard clearance: 0.25 to 0.40 mm (0.00984 to 0.0157 in.)
  
  If the clearance is out of specification, replace the 1st gear, or No. 1 transmission clutch hub.
  
  Fig 1: Measuring 1st Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 2nd gear thrust clearance.
  Standard clearance: 0.10 to 0.35 mm (0.00394 to 0.0138 in.)
  
  If the clearance is not as specified, replace the No. 1 transmission clutch hub, 2nd gear, or 3rd driven gear.
  
  Fig 2: Measuring 2nd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 1ST GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 1st gear radial clearance.

Standard clearance

STANDARD CLEARANCE

Bearing	Standard Clearance mm (in.)
KOYO made	0.009 to 0.053 (0.000354 to 0.00209)
NSK made	0.009 to 0.051 (0.000354 to 0.00201)

If the clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.

Fig 3: Measuring 1st Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2ND GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 2nd gear radial clearance.

Standard clearance

STANDARD CLEARANCE

Bearing	Standard Clearance mm (in.)
KOYO made	0.009 to 0.053 (0.000354 to 0.00209)
NSK made	0.009 to 0.051 (0.000354 to 0.00201)

Fig 4: Measuring 2nd Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the clearance is out of specification, replace the 2nd gear and 2nd gear needle roller bearing.

INSPECT OUTPUT SHAFT

Using V-blocks and a dial indicator, inspect the shaft for runout.
Maximum runout: 0.03 mm (0.00118 in.)

If runout exceeds the maximum, replace the output shaft.

Fig 5: Inspecting Input Shaft For Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Outside diameter

OUTSIDE DIAMETER

Part	Standard Outside Diameter mm (in.)	Minimum Outside Diameter mm (in.)
A	37.610 to 37.626 (1.4807 to 1.4813)	37.610 (1.4807)
B	34.502 to 34.512 (1.3583 to 1.3587)	34.502 (1.3583)

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

Fig 6: Measuring Outside Diameter Of Output Shaft Journal Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2ND GEAR

Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Inside diameter mm (in.)

INSIDE DIAMETER REFERENCE CHART

Standard Inside Diameter mm (in.)	Maximum Inside Diameter mm (in.)
50.009 to 50.025 (1.9689 to 1.9695)	50.025 (1.9695)

If the inside diameter exceeds the maximum, replace the 2nd gear.

Fig 7: Measuring Inside Diameter Of 2nd Gear

INSPECT 1ST GEAR

Using a cylinder gauge, measure the inside diameter of the 1st gear.

Inside diameter mm (in.)

INSIDE DIAMETER REFERENCE CHART

Standard Inside Diameter mm (in.)	Maximum Inside Diameter mm (in.)
51.009 to 51.025 (2.0082 to 2.0089)	51.025 (2.0089)

If the inside diameter exceeds the maximum, replace the 1st gear.

Fig 8: Measuring Inside Diameter Of 1st Gear

INSPECT NO. 2 SYNCHRONIZER RING SET
1. Coat the 2nd gear cone with gear oil.
2. Check for wear and damage.
3. Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.
4. Check that the ring locks.
  If the synchronizer ring set does not lock, replace the synchronizer ring set.
  
  Fig 9: Inspecting No. 2 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.
  Standard clearance:
  
  0.70 to 1.45 mm (0.0276 to 0.0571 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring set.
INSPECT NO. 1 SYNCHRONIZER RING SET
1. Coat the 1st gear cone with gear oil.
  
  Fig 10: Measuring Clearance Between Synchronizer Ring And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check for wear and damage.
3. Turn the synchronizer ring set in one direction while pushing it against the 1st gear cone.
4. Check that the ring set locks.
  If the synchronizer ring set does not lock, replace the synchronizer ring set.
  
  Fig 11: Inspecting No. 1 Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.
  Standard clearance:
  
  0.70 to 1.45 mm (0.0276 to 0.0571 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring set.
  
  Fig 12: Measuring Clearance Between Synchronizer Ring And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE GEAR
1. Using a vernier caliper, measure the width of the reverse gear groove and thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance.
  Standard clearance:
  
  0.15 to 0.35 mm (0.00591 to 0.0138 in.) {A - B}
  
  If the clearance is not as specified, replace the reverse gear and No. 1 gear shift fork with new ones.
  
  Fig 13: Identifying Width Of Reverse Gear Groove And Thickness Of Claw Part On No. 1 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 TRANSMISSION CLUTCH HUB
1. Check the sliding condition between the No. 1 transmission clutch hub and the reverse gear.
2. Check the tip of the spline gear on the sleeve of the reverse gear for wear.
  If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.
  
  Fig 14: Inspecting No. 1 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002