Transfer Assembly: Inspection

INSPECT TRANSFER INPUT SHAFT
1. Using a micrometer, measure the outer diameter of the input shaft journal surface.
  Minimum diameter:
  
  47.59 mm (1.8736 in.)
  
  If the outer diameter is less than the minimum, replace the input shaft.
  
  Fig 1: Measuring Outer Diameter Of Input Shaft Journal Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the inside diameter of the input shaft bushing.
  Maximum diameter:
  
  39.14 mm (1.5409 in.)
  
  If the inside diameter exceeds the maximum, replace the input shaft.
  
  Fig 2: Measuring Inside Diameter Of Input Shaft Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SYNCHRONIZER RING
1. Turn the ring and confirm that the input shaft and synchronizer ring are engaged with each other.
  
  Fig 3: Inspecting Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the synchronizer ring and the input shaft spline.
  Standard clearance:
  
  1.05 to 1.85 mm (0.0413 to 0.0728 in.)
  
  Minimum clearance:
  
  0.80 mm (0.0315 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring.
  
  Fig 4: Measuring Clearance Between Synchronizer Ring And Input Shaft Spline
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PLANETARY PINION GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.
  Standard clearance:
  
  0.11 to 0.84 mm (0.0043 to 0.0331 in.)
  
  Maximum clearance:
  
  0.84 mm (0.0331 in.)
  
  If the clearance exceeds the maximum, replace the planetary gear assembly.
  
  Fig 5: Measuring Thrust Clearance Of Planetary Pinion Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the radial clearance of the planetary pinion gear.
  Standard clearance:
  
  0.009 to 0.038 mm (0.0004 to 00015 in.)
  
  Maximum clearance:
  
  0.038 mm (0.0015 in.)
  
  If the clearance exceeds the maximum, replace the planetary gear assembly.
  
  Fig 6: Measuring Radial Clearance Of Planetary Pinion Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER REAR OUTPUT SHAFT
1. Using a micrometer, measure the outer diameter of the output shaft rear journal surface.
  Minimum diameter:
  
  27.98 mm (1.1016 in.) for part A
  
  36.98 mm (1.4561 in.) for part B
  
  If the outer diameter is less than the minimum, replace the output shaft rear.
  
  Fig 7: Measuring Outer Diameter Of Output Shaft Rear Journal Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DRIVE SPROCKET RADIAL CLEARANCE
1. Using a dial indicator, measure the radial clearance between the sprocket and the shaft with the needle roller bearing installed.
  Standard clearance:
  
  0.010 to 0.055 mm (0.0004 to 0.0022 in.)
  
  Maximum clearance:
  
  0.055 mm (0.0022 in.)
  
  Fig 8: Measuring Radial Clearance Between Sprocket And Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft and drive sprocket bearing.
INSPECT GEAR SHIFT FORK NO. 1 AND HUB SLEEVE CLEARANCE
1. Using a feeler gauge, measure the clearance between the gear shift fork No. 1 and drive clutch sleeve.
  Maximum clearance:
  
  1.0 mm (0.039 in.)
  
  If the clearance exceeds the maximum, replace the gear shift fork No. 1 and drive clutch sleeve.
  
  Fig 9: Measuring Clearance Between Gear Shift Fork And Drive Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GEAR SHIFT FORK NO. 2 AND HUB SLEEVE CLEARANCE
1. Using a feeler gauge, measure the clearance between the gear shift fork No. 2 and high and low clutch sleeve.
  Maximum clearance:
  
  1.0 mm (0.039 in.)
  
  If the clearance exceeds the maximum, replace the gear shift fork No. 2 and high and low clutch sleeve.
  
  Fig 10: Measuring Clearance Between Gear Shift Fork No. 2 And High And Low Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002