Input Shaft: Inspection

WARNING: This page is about a different variant/trim than selected.

INSPECT 4TH GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 4th gear thrust clearance.
  Standard clearance: 0.10 to 0.57 mm (0.00394 to 0.0224 in.)
  
  If the clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear, or input shaft rear radial ball bearing.
  
  Fig 1: Measuring 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 (0.00394 to 0.0138 in.)
  
  If the clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear, or input shaft.
  
  Fig 2: Measuring 3rd Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 4TH GEAR RADIAL CLEARANCE

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

Standard Clearance

STANDARD CLEARANCE

Bearing	Standard Clearance mm (in.)
KOYO made	0.009 to 0.053 (0.000354 to 0.00208)
NSK made	0.009 to 0.051 (0.000354 to 0.00201)

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

Fig 3: Measuring 4th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 3RD GEAR RADIAL CLEARANCE

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

Standard Clearance

STANDARD CLEARANCE

Bearing	Standard Clearance mm (in.)
KOYO made	0.009 to 0.053 (0.000354 to 0.00208)
NSK made	0.009 to 0.051 (0.000354 to 0.00201)

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

Fig 4: Measuring 3rd Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT INPUT SHAFT

Using V-blocks and a dial indicator, inspect the shaft for runout.
Maximum runout: 0.03 mm (0.00118 in.)

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

Fig 5: Inspecting Input Shaft For Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Outside Diameter

OUTSIDE DIAMETER

Part	Standard Outside Diameter mm (in.)	Minimum Outside Diameter mm (in.)
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)

Fig 6: Measuring Outside Diameter Of Input Shaft Journal Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

Inside Diameter

INSIDE DIAMETER

Standard Inside Diameter mm (in.)	Maximum Inside Diameter mm (in.)
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.

Fig 7: Measuring Inside Diameter Of 4th Gear

INSPECT 3RD GEAR

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

Inside Diameter

INSIDE DIAMETER

Standard Inside Diameter mm (in.)	Maximum Inside Diameter mm (in.)
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.

Fig 8: Measuring Inside Diameter Of 3rd Gear

INSPECT NO. 4 SYNCHRONIZER RING
1. Coat the 4th gear cone with gear oil. Turn the No. 4 synchronizer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks. If the No. 4 synchronizer ring does not lock, replace the ring or the 4th gear.
  
  Fig 9: Inspecting No. 4 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the 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 the clearance is not as specified, replace the synchronizer ring.
  
  Fig 10: Measuring Clearance Between No. 4 Synchronizer 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: 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 not as specified, replace the No. 3 synchronizer ring.
  
  Fig 12: Measuring Clearance Between No. 3 Synchronizer Ring 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 No. 2 Transmission Hub Sleeve And No. 2 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a vernier caliper, 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 (0.00433 to 0.0272 in.) {A - B}
  
  If the clearance is not as specified, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork with new ones.
  
  Fig 14: Identifying Width Of No. 3 Transmission Hub Sleeve Groove And Thickness Of Claw Part On No. 1 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002