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: Measuring 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 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 (0.00437 to 0.0335 in.)
  
  Maximum clearance: 0.85 mm (0.0335 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 (0.000354 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

REAR TRANSFER OUTPUT SHAFT SPECIFIED CONDITION

Journal	Specified Condition
A	40 mm (1.58 in.)
B	49 mm (1.93 in.)

Fig 5: Identifying Output Shaft Journal

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

INSPECT NO. 1 TRANSFER GEAR SHIFT FORK AND HUB SLEEVE
1. Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.
  Maximum clearance: 2.1 mm (0.0827 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 HUB SLEEVE
1. Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.
  Maximum clearance: 1.0 mm (0.0394 in.)
  
  If the clearance is greater than the maximum, replace the clutch sleeve or shift fork.
  
  Fig 7: Measuring Clearance Between Clutch Sleeve And Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002