Transfer Assembly: Inspection

INSPECT TRANSFER INPUT SHAFT
1. Using a micrometer, measure the diameter of the input shaft journal surface.
  Minimum diameter: 68 mm (2.68 in.)
  
  If the diameter is less than the minimum, replace the input shaft.
  
  Fig 1: Identifying Transfer Input Shaft Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the inside diameter of the input shaft bush.
  Maximum inside diameter: 46 mm (1.81 in.)
  
  If the inside diameter is greater than the maximum, replace the input shaft.
  
  Fig 2: Measuring Inside Diameter Of Input Shaft Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY
1. Using a feeler gauge, measure the thrust clearance of the pinion gear.
  Standard clearance: 0.11 to 0.85 mm (0.00434 to 0.0334 in.)
  
  Maximum clearance: 0.85 mm (0.0334 in.)
  
  If the clearance is greater than the maximum, replace the low planetary gear assembly.
  
  Fig 3: Measuring Thrust Clearance Of Pinion Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY
1. Using a dial indicator, measure the radial clearance of the pinion gear.
  Standard clearance: 0.011 to 0.038 mm (0.000434 to 0.00150 in.)
  
  Maximum clearance: 0.038 mm (0.00150 in.)
  
  If the clearance is greater than the maximum, replace the low planetary gear assembly.
  
  Fig 4: Measuring Radial Clearance Of Pinion Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT REAR TRANSFER OUTPUT SHAFT

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

Minimum Diameter

OUTPUT SHAFT JOURNAL DIAMETER SPECIFICATION

Journal	Specified Condition
A	38 mm (1.50 in.)
B	42 mm (1.65 in.)
C	49 mm (1.93 in.)

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

Fig 5: Measuring Diameter Of Output Shaft Journal

INSPECT NO. 1 TRANSFER GEAR SHIFT FORK AND FRONT DRIVE CLUTCH SLEEVE
1. Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.
  Maximum clearance: 0.8 mm (0.0315 in.)
  
  If the clearance is greater than the maximum, replace the clutch sleeve or shift fork.
  
  Fig 6: Measuring Clearance Between Clutch Sleeve And Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 TRANSFER GEAR SHIFT FORK AND HIGH AND LOW CLUTCH SLEEVE
1. Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.
  Maximum clearance: 3 mm (0.118 in.)
  
  If the clearance is greater than the maximum, replace the clutch sleeve or shift fork.
  
  Fig 7: Inspecting No. 2 Transfer Gear Shift Fork And High And Low Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 SYNCHRONIZER RING
1. Apply gear oil to the cone of the input shaft, and check that it does not turn in both directions while pushing the No. 1 synchronizer ring. If it can turn, replace the No. 1 synchronizer ring.
  
  Fig 8: Inspecting No. 1 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Push the No. 1 synchronizer ring to the cone of the input shaft. Measure the clearance between the No. 1 synchronizer ring and input shaft.
  Standard Clearance: 0.86 to 1.54 mm (0.0339 to 0.0606 in.)
  
  Minimum Clearance: 0.86 mm (0.0334 in.)
  
  If the clearance is not as specified, replace the No. 1 synchronizer ring with a new one.
  
  Fig 9: Measuring Clearance Between No. 1 Synchronizer Ring And Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER SYNCHRONIZER RING SET
1. Apply gear oil to the cone of the transfer sprocket sub-assembly, and check that it does not turn in both directions while pushing the transfer synchronizer ring set. If it can turn, replace the transfer synchronizer ring set.
  
  Fig 10: Inspecting Transfer Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Push the transfer synchronizer ring set to the cone of the transfer sprocket sub-assembly. Measure the clearance between the transfer synchronizer ring set and transfer sprocket sub-assembly.
  Standard Clearance: 1.18 to 2.22 mm (0.0465 to 0.0874 in.)
  
  Minimum Clearance: 1.18 mm (0.0465 in.)
  
  If the clearance is not as specified, replace the transfer synchronizer ring set with a new one.
  
  Fig 11: Measuring Clearance Between Transfer Synchronizer Ring Set And Transfer Sprocket Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002