Output Shaft: Inspection

1. Check for wear or damage.
2. Check the braking effect of the synchronizer ring.

   Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.

   If the braking effect is insufficient, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

   NOTE: Ensure the fine lapping compound is completely washed off after rubbing. 
3. Check again the braking effect of the synchronizer ring.
   Fig 1: Inspecting 1st Gear Synchronizer Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
   1. Minimum clearance: 0.7 mm (0.028 in.) 

   If the clearance is less than the minimum, replace the synchronizer ring and gear cone by applying a small amount of fine lapping compound.

   NOTE: Ensure the fine lapping compound is completely washed off after rubbing. 

Fig 2: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check for wear or damage.
2. Install the synchronizer inner ring, middle ring and outer ring to each gear.
   Fig 3: Inspecting 2nd & 3rd Gears Synchronizer Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.

   If it does not lock, replace the synchronizer ring.

   Fig 4: Checking Braking Effect Of Synchronizer Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end.

   Minimum clearance: 

   1. 2nd gear: 0.74 mm (0.0291 in.) 
   2. 3rd gear: 0.70 mm (0.0276 in.) 

   If the clearance is less than the minimum, replace the synchronizer ring.

Fig 5: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a feeler gauge, measure the clearance between the hub sleeves and shift forks.

1. Maximum clearance: 0.5 mm (0.020 in.) 

If the clearance exceeds the maximum, replace the shift fork or hub sleeve.

Fig 6: Inspecting Shift Fork & Hub Sleeve Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using vernier calipers, measure the output shaft flange thickness.
   1. Minimum thickness: 5.70 mm (0.2244 in.) 

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

   Fig 7: Inspecting Output Shaft & Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using vernier calipers, measure the inner race flange thickness.
   1. Minimum thickness: 4.78 mm (0.1881 in.) 

   If the thickness is less than the minimum, replace the inner race.

   Fig 8: Measuring Inner Race Flange Thickness

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a micrometer, measure the outer diameter of the output shaft journal.

   Minimum diameter: 

   1. 2nd gear: 42.975 mm (1.6919 in.) 
   2. 3rd gear: 31.969 mm (1.2586 in.) 

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

   Fig 9: Measuring Outer Diameter Of Output Shaft Journal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a micrometer, measure the outer diameter of the inner race.
   1. Minimum diameter: 42.975 mm (1.6919 in.) 

   If the outer diameter is less than the minimum, replace the inner race.

   Fig 10: Measuring Outer Diameter Of Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a dial indicator, check the shaft runout.
   1. Maximum runout: 0.03 mm (0.0012 in.) 

   If the runout exceeds the maximum, replace the output shaft.

   Fig 11: Checking Output Shaft Runout

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002