Output Shaft: Inspection

INSPECT OUTPUT SHAFT
1. Using a dial indicator and 2 V-blocks, check the output shaft runout.
  Maximum runout:
  
  0.015 mm (0.000591 in.)
  
  If the runout exceeds the maximum, replace the output shaft.
  
  Fig 1: Checking Output Shaft Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the outer diameter of the output shaft journal surface at the locations indicated.
  Standard outer diameter:
  
  Part A:
  
  31.985 to 32.000 mm (1.2592 to 1.2598 in.)
  
  Part B:
  
  37.985 to 38.000 mm (1.4955 to 1.4961 in.)
  
  Part C:
  
  32.985 to 33.000 mm (1.2986 to 1.2992 in.)
  
  If any of the outer diameters are less than the minimum, replace the output shaft.
  
  Fig 2: Measuring Outer Diameter Of Output Shaft Journal Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND GEAR
1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.
  Standard inside diameter:
  
  38.015 to 38.031 mm (1.4967 to 1.4972 in.)
  
  Maximum inside diameter:
  
  38.031 mm (1.4972 in.)
  
  If the inside diameter exceeds the maximum, replace the 1st gear.
  
  Fig 3: Measuring Inside Diameter Of 2Nd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1ST GEAR
1. Using a cylinder gauge, measure the inside diameter of the 1st gear.
  Standard inside diameter:
  
  44.015 to 44.031 mm (1.7328 to 1.7335 in.)
  
  Maximum inside diameter:
  
  44.031 mm (1.7335 in.)
  
  If the inside diameter exceeds the maximum, replace the 1st gear.
  
  Fig 4: Measuring Inside Diameter Of 1St Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1 ST GEAR THRUST WASHER
1. Using a micrometer, measure the 1st gear thrust washer.
  Standard thickness:
  
  5.975 to 6.025 mm (0.2352 to 0.2372 in.)
  
  Minimum thickness:
  
  5.975 mm (0.2352 in.)
  
  If the thickness is less than the minimum, replace the 1st gear thrust washer.
  
  Fig 5: Measuring 1St Gear Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 SYNCHRONIZER RING SET (FOR 2ND GEAR)
1. Coat the 2nd gear cone and No. 2 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
2. Install the inner ring onto the 2nd gear.
  
  Fig 6: Identifying Inner Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the middle ring onto the 2nd gear.
  
  Fig 7: Identifying Middle Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the outer ring onto the 2nd gear.
  
  Fig 8: Identifying Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check for wear and damage.
6. Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.
7. Check that the ring set locks.
  If the synchronizer ring set does not lock, replace the synchronizer ring set.
  
  Fig 9: Checking Ring Set Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.
  Standard clearance:
  
  0.60 to 1.40 mm (0.0236 to 0.0551 in.)
  
  Minimum clearance:
  
  0.60 mm (0.0236 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring set.
  
  Fig 10: Measuring Clearance Between Synchronizer Ring And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)
1. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
2. Install the inner ring onto the 1st gear.
  
  Fig 11: Identifying Inner Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the middle ring onto the 1st gear.
  
  Fig 12: Identifying Middle Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the outer ring onto the 1st gear.
  
  Fig 13: Identifying Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check for wear and damage.
6. Turn the synchronizer ring set in one direction while pushing it against the 1st gear cone.
7. Check that the ring set locks.
  If the synchronizer ring set does not lock, replace the synchronizer ring set.
  
  Fig 14: Checking Ring Set Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.
  Standard clearance:
  
  0.60 to 1.40 mm (0.0236 to 0.0551 in.)
  
  Minimum clearance:
  
  0.60 mm (0.0236 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring set.
  
  Fig 15: 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 (A) and the thickness of the claw part on the reverse shift fork (B), and calculate the clearance.
  Standard clearance (A - B):
  
  0.15 to 0.35 mm (0.00591 to 0.0138 in.)
  
  If the clearance is out of specification, replace the reverse gear and reverse shift fork.
  
  Fig 16: Measuring Width Of Reverse Gear Groove (A) And Thickness Of Claw Part On Reverse Shift Fork (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 TRANSMISSION CLUTCH HUB
1. Check that the No. 1 transmission clutch hub and reverse gear slide smoothly.
2. Check that the edges of the reverse gear spline gear are not worn down.
  
  Fig 17: Checking No. 1 Transmission Clutch Hub And Reverse Gear Slide Smoothly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002