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 Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the inside diameter of the input shaft bushing.
  Maximum diameter:
  
  48.14 mm (1.8593 in.)
  
  If the inside diameter exceeds the maximum, replace the input shaft.
  
  Fig 2: Measuring Inside Diameter Of Input Shaft Bushing Using Dial Indicator
  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 3: Measuring Thrust Clearance Of Planetary Pinion Gear Using Feeler Gauge
  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 4: Measuring Radial Clearance Of Planetary Pinion Gear Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DRIVE SPROCKET THRUST CLEARANCE
1. Using a feeler gauge, measure the thrust clearance of the drive sprocket.
  Standard clearance:
  
  0.15 to 0.24 mm (0.0059 to 0.0094 in.)
  
  Maximum clearance:
  
  0.24 mm (0.0094 in.)
  
  If the clearance exceeds the maximum, replace the drive sprocket.
  
  Fig 5: Measuring Thrust Clearance Of Drive Sprocket Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DRIVE SPROCKET RADIAL CLEARANCE
1. Using a dial indicator, measure the radial clearance of the drive sprocket.
  Standard clearance:
  
  0.01 to 0.06 mm (0.0004 to 0.0024 in.)
  
  Maximum clearance:
  
  0.06 mm (0.0024 in.)
  
  If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft or needle roller bearing.
  
  Fig 6: Measuring Radial Clearance Of Drive Sprocket Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER OUTPUT SHAFT REAR
1. Using a micrometer, measure the outer diameter of the output shaft rear journal surface.
  Standard diameter:
  
  Part A:
  
  27.98 to 27.99 mm (1.1016 to 1.1020 in.)
  
  Part B:
  
  31.98 to 32.00 mm (1.2591 to 1.2598 in.)
  
  Part C:
  
  34.98 to 35.00 mm (1.3772 to 1.3780 in.)
  
  Part D:
  
  36.98 to 37.00 mm (1.4559 to 1.4567 in.)
  
  Minimum diameter:
  
  Part A:
  
  27.98 mm (1.1016 in.)
  
  Part B:
  
  31.98 mm (1.2591 in.)
  
  Part C:
  
  34.98 mm (1.3772 in.)
  
  Part D:
  
  36.98 mm (1.4559 in.)
  
  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 Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 2 CLEARANCE
1. Using vernier calipers, measure the thickness of the gear shift fork No. 2 claw.
  Thickness:
  
  10 mm (0.3937 in.)
2. Using vernier calipers, measure the groove of the high and low clutch sleeve.
  Distance:
  
  10.5 mm (0.4134 in.)
3. Calculate a clearance between the high and low clutch sleeve and gear shift fork No. 2 clearance.
  Standard clearance:
  
  0.26 to 0.84 mm (0.0102 to 0.0331 in)
  
  Maximum clearance:
  
  0.84 mm (0.0331 in.)
  
  If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No. 2.
  
  Fig 8: Measuring High & Low Clutch Sleeve & Gear Shift Fork No. 2 Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT DRIVE CLUTCH SLEEVE AND CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY CLEARANCE
1. Using vernier calipers, measure the thickness of the CTR differential lock fork claw.
  Thickness:
  
  10 mm (0.3937 in.)
2. Using vernier calipers, measure the groove of the front drive clutch sleeve.
  Distance:
  
  10.5 mm (0.4134 in.)
3. Calculate a clearance between the front drive clutch sleeve arid CTR differential lock fork.
  Standard clearance:
  
  0.26 to 0.84 mm (0.0102 to 0.0331 in.)
  
  Maximum clearance:
  
  0.84 mm (0.0331 in.)
  
  If the clearance exceeds the maximum, replace the front drive clutch sleeve or CTR differential lock fork.
  
  Fig 9: Identifying Front Drive Clutch Sleeve & CTR Differential Lock Fork Sub-Assembly Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE
1. Check that the tip of the spline gear of the high and low clutch sleeve is not worn.
2. Install the high and low clutch sleeve to the center differential case and check that the high and low clutch sleeve moves smoothly.
INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE
1. Check that the tip of the spline gear of the front drive clutch sleeve is not worn.
2. Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly.