Input Shaft: Inspection

INSPECT INPUT SHAFT

Using V-blocks and dial indicator, measure the shaft for runout.
Maximum runout: 0.03 mm (0.0012 in.)

If the runout is greater than the maximum, replace the input shaft.

Fig 1: Measuring Shaft For Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the diameter of the input shaft journal surface.

Standard diameter

STANDARD SPECIFICATION

Journal Position	Specified Condition
A	35.984 to 36.000 mm (1.4167 to 1.4173 in.)
B	35.984 to 36.000 mm (1.4167 to 1.4173 in.)
C	27.957 to 27.972 mm (1.1007 to 1.1013 in.)

Fig 2: Measuring Outside Diameter Of Input Shaft Journal Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Minimum diameter

MINIMUM DIAMETER SPECIFICATION

Journal Position	Specified Condition
A	35.984 mm (1.4167 in.)
B	35.984 mm (1.4167 in.)
C	27.957 mm (1.1007 in.)

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

INSPECT 4TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
  Standard inside diameter: 42.009 to 42.025 mm (1.6539 to 1.6545 in.)
  
  Maximum inside diameter: 42.025 mm (1.6545 in.)
  
  If the inside diameter is greater than the maximum, replace the 4th gear.
  
  Fig 3: Measuring Inside Diameter Of 4Th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR
1. Using a cylinder gauge, measure the inside diameter.
  Standard inside diameter: 43.009 to 43.025 mm (1.6933 to 1.6939 in.)
  
  Maximum inside diameter: 43.025 mm (1.6939 in.)
  
  If the inside diameter is greater than the maximum, replace the 3rd gear.
  
  Fig 4: Measuring Inside Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 4 SYNCHRONIZER OUTER RING
1. Coat the 4th gear cone with gear oil. Turn the No. 4 synchronizer outer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks.
  If the No. 4 synchronizer outer ring does not lock, replace the ring or the 4th gear.
  
  Fig 5: Installing 2Nd Synchronizer Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the No. 4 synchronizer outer ring back and 4th gear spline end.
  Standard clearance: 0.7 to 1.45 mm (0.0276 to 0.0571 in.)
  
  If the clearance is out of the specification, replace the No. 4 synchronizer outer ring.
  
  Fig 6: Measuring Clearance Between 2Nd Synchronizer Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 SYNCHRONIZER RING
1. Coat the 3rd gear cone with gear oil. Turn the No. 3 synchronizer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks. If the No. 3 synchronizer ring does not lock, replace the ring or the 3rd gear.
  
  Fig 7: Inspecting No. 3 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring back and 3rd gear spline end.
  Standard clearance: 0.65 to 1.75 mm (0.0256 to 0.0689 in.)
  
  If the clearance is out of the specification, replace the No. 3 synchronizer ring.
  
  Fig 8: Measuring Clearance Between No. 3 Synchronizer Ring Back And 3Rd Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 TRANSAXLE HUB SLEEVE
1. Inspect the sliding condition between the No. 2 transaxle hub sleeve and No. 2 transaxle clutch hub.
2. Inspect the tip of the spline gear on the No. 2 transaxle hub sleeve for wear.
  If any defects are found, replace the transaxle hub sleeve or the transaxle clutch hub.
  
  Fig 9: Inspecting No. 2 Transmission Hub Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the width of the No. 2 transaxle hub sleeve groove (A) and the thickness of the claw part on the No. 2 gear shift fork (B), and calculate the clearance.
  Standard clearance: A - B = 0.11 to 0.69 mm (0.0043 to 0.0272 in.)
  
  If the clearance is out of the specification, replace the No. 2 transaxle hub sleeve and No. 2 gear shift fork with new ones.
  
  Fig 10: Identifying Width Of No. 2 Transaxle Hub Sleeve Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002