Manual Transaxle Unit: Inspection

INSPECT NO. 3 SYNCHRONIZER RING
1. Check for wear and damage.
2. Coat the 5th gear cone with gear oil.
3. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone.
4. Check that the ring locks.
  If the synchronizer ring does not lock, replace the synchronizer ring.
  
  Fig 1: Inspecting No. 3 Synchronizer Ring
  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:
  
  0.75 to 1.65 mm (0.0295 to 0.0649 in.)
  
  Minimum clearance:
  
  0.75 mm (0.0295 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring.
  
  Fig 2: Measuring Clearance Between Synchronizer Ring And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 TRANSMISSION HUB SLEEVE
1. Check the sliding condition between the No. 3 transmission hub sleeve and the No. 3 transmission clutch hub.
2. Check that the edges of the No. 3 transmission hub sleeve spline gear are not worn down.
  
  Fig 3: Checking Sliding Condition Between No. 3 Transmission Hub Sleeve And No. 3 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a vernier caliper, measure the width of the No. 3 transmission 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):
  
  0.3 to 0.5 mm (0.0118 to 0.0197 in.)
  
  If the clearance exceeds the standard, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork.
  
  Fig 4: Measuring Width Of No. 3 Transmission Hub Sleeve Groove (A) And Thickness Of Claw Part On No. 3 Gear Shift Fork (B)
  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:
  
  29.915 to 29.931 mm (1.1778 to 1.1783 in.)
  
  Maximum inside diameter:
  
  29.931 mm (1.1783 in.)
  
  If the inside diameter exceeds the maximum, replace the 5th gear.
  
  Fig 5: Measuring Inside Diameter Of 5Th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
1. Using a caliper gauge, inspect the reverse idler gear.
  Standard inside diameter:
  
  18.040 to 18.058 mm (0.7102 to 0.7109 in.)
  
  Maximum inside diameter:
  
  18.058 mm (0.7109 in.)
  
  If the inside diameter exceeds the maximum, replace the reverse idler gear sub-assembly.
2. Using a micrometer, inspect the reverse idler gear shaft.
  Standard outer diameter:
  
  17.966 to 17.984 mm (0.7073 to 0.7080 in.)
  
  Minimum outer diameter:
  
  17.966 mm (0.7073 in.)
  
  If the outer diameter is less than the minimum, replace the reverse idler gear shaft.
  
  Fig 6: Inspecting Reverse Idler Gear Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002