Input Shaft: Inspection

INSPECT 4TH GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 4th gear thrust clearance.
  Standard clearance: 0.10 to 0.57 mm (0.0039 to 0.0224 in.)
  
  If clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear, or input shaft rear radial ball bearing.
  
  Fig 1: Using Feeler Gauge To Measure 4Th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 3rd gear thrust clearance.
  Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 in.)
  
  If clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear, or input shaft.
  
  Fig 2: Using Dial Indicator To Measure 2nd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 4TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 4th gear radial clearance.

Fig 3: Measuring 4th Gear Radial Clearance Using Dial Indicator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard clearance mm (in.)

4TH GEAR RADIAL CLEARANCE

Bearing	Standard clearance
KOYO made	0.009 to 0.053 (0.0004 to 0.0021)
NSK made	0.009 to 0.051 (0.0004 to 0.0020)

If clearance is out of specification, replace the 4th gear, needle roller bearing, or input shaft.

INSPECT 3RD GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 3rd gear radial clearance.

Fig 4: Using Dial Indicator To Measure 3rd Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard clearance mm (in.)

3RD GEAR RADIAL CLEARANCE

Bearing	Standard clearance
KOYO made	0.009 to 0.053 (0.0004 to 0.0021)
NSK made	0.009 to 0.051 (0.0004 to 0.0020)

If clearance is out of specification, replace the 3rd gear, needle roller bearing, or input shaft.

INSPECT INPUT SHAFT

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

If runout exceeds the maximum, replace the input shaft.

Fig 5: Using V-Block And Dial Indicator To Inspect Shaft For Run Out
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 6: Measuring Outside Diameter Of Input Shaft Journal Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Outside diameter mm (in.)

INPUT SHAFT JOURNAL SURFACE OUTSIDE DIAMETER

Part	Standard outside diameter	Minimum outside diameter
A	35.984 to 36.000 (1.4167 to 1.4173)	35.984 (1.4167)
B	35.984 to 36.000 (1.4167 to 1.4173)	35.984 (1.4167)
C	27.957 to 27.972 (1.1007 to 1.1013)	27.957 (1.1007)

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

INSPECT 4TH GEAR

Using a cylinder gauge, measure the inside diameter of the 4th gear.

Fig 7: Measuring Inside Diameter Of 4Th Gear

Inside diameter: mm (in.)

4TH GEAR INSIDE DIAMETER

Standard Inside diameter	Maximum inside diameter
42.009 to 42.025 (1.6539 to 1.6545)	42.025 (1.6545)

If the inside diameter exceeds the maximum, replace the 4th gear.

INSPECT 3RD GEAR

Using a cylinder gauge, measure the inside diameter of the 3rd gear.

Fig 8: Measuring Inside Diameter Of 4Th Gear

Inside diameter: mm (in.)

3RD GEAR INSIDE DIAMETER

Standard Inside diameter	Maximum Inside diameter
43.009 to 43.025 (1.6933 to 1.6939)	43.025 (1.6939)

If the inside diameter exceeds the maximum, replace the 3rd gear.

INSPECT 2ND SYNCHRONIZER OUTER RING
1. Coat the 4th gear cone with gear oil. Turn the 2nd synchronizer outer ring (No. 4 synchronizer ring) in one direction while pushing it against the 4th gear cone. Check that the ring locks.
  If the 2nd synchronizer outer ring does not lock, replace the ring or the 4th gear.
  
  Fig 9: Turning 2nd Synchronizer Outer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the synchronizer outer ring (No. 4 synchronizer ring) back and 4th gear spline end.
  Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.0650 in.)
  
  If clearance is out of specification, replace the synchronizer ring.
  
  Fig 10: Measuring Clearance Between Synchronizer Outer Ring Back And 4Th Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 SYNCHRONIZER RING
1. Coat the 3rd gear cone with gear oil. Turn the synchronizer outer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks.
  If the synchronizer outer ring does not lock, replace the ring or the 3rd gear.
  
  Fig 11: Turning Synchronizer Outer 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 clearance is out of specification, replace the No. 3 synchronizer ring.
  
  Fig 12: Using Feeler Gauge To Measure Clearance Between Synchronizer Ring No. 3 Back And 3rd Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 TRANSMISSION HUB SLEEVE
1. Inspect the sliding condition between the No. 2 transmission hub sleeve and No. 2 transmission clutch hub.
2. Inspect the tip of the spline gear on the No. 2 transmission hub sleeve for wear.
  If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.
  
  Fig 13: Checking Sliding Condition Between Transmission Hub Sleeve No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove and the thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance.
  Standard clearance: 0.11 to 0.69 mm (0.0043 to 0.0272 in.) {A - B}
  
  If clearance is out of specification, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork with new ones.
  
  Fig 14: Measuring Width Of Transmission Hub Sleeve No. 3 Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002