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.
   Fig 1: Checking Braking Effect Of Synchronizer Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check again the braking effect of the synchronizer ring.
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.) 
   Fig 2: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Check for wear or damage.
2. Install the synchronizer inner ring, middle ring and outer ring to each gear.
   Fig 3: Installing Synchronizer Inner Ring, Middle Ring And Outer Ring To Each Gear

   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.
   1. Minimum clearance: 
   2. 2nd gear: 0.74 mm (0.0291 in.) 
   3. 3rd gear: 0.70 mm (0.0276 in.) 
   Fig 5: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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: Measuring Clearance Between Hub Sleeves And Shift Forks

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1. Using vernier calipers, measure the output shaft flange thickness.
   1. Minimum thickness: 5.70 mm (0.2244 in.) 
   Fig 7: Using Vernier Calipers To Measure Output Shaft Flange Thickness

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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.
   1. Minimum diameter: 
   2. 2nd gear: 42.975 mm (1.6919 in.) 
   3. 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: Using Dial Indicator To Check Shaft Runout

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002