Manual Transaxle Unit: Inspection

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

INSPECT 6TH GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 6th gear thrust clearance.
  Standard clearance:
  
  0.10 to 0.60 mm (0.0039 to 0.0236 in.)
  
  Fig 1: Inspecting 6th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 5th gear thrust clearance.
  Standard clearance:
  
  0.10 to 0.62 mm (0.0039 to 0.0244 in.)
  
  Fig 2: Inspecting 5th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 6TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 6th gear radial clearance.
  Standard clearance:
  
  0.009 to 0.050 mm (0.0004 to 0.0020 in.)
  
  If the clearance is out of the specification, replace the 6th gear needle roller bearing.
  
  Fig 3: Inspecting 6th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 5th gear radial clearance.
  Standard clearance:
  
  0.015 to 0.056 mm (0.0006 to 0.0022 in.)
  
  If the clearance is out of specification, replace the 5th gear needle roller bearing.
  
  Fig 4: Inspecting 5th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSMISSION HUB SLEEVE NO. 3
1. Check the sliding condition between the transmission hub sleeve No. 3 and transmission clutch hub No. 3.
2. Check that the tip of the spline gear of the transmission hub sleeve No. 3 is not worn down.
  
  Fig 5: Inspecting Transmission Hub Sleeve No.3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the width of the transmission hub sleeve No. 3 groove (A) and the thickness of the claw part on the gear shift fork No. 3 (B), and calculate the clearance.
  Standard clearance (A - B):
  
  0.31 to 0.89 mm (0.0122 to 0.035 in.)
  
  If the clearance is out of specification, replace the transmission hub sleeve No. 3 and gear shift fork No. 3.
  
  Fig 6: Measuring Width Of Transmission Hub Sleeve No. 3 Groove (A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SYNCHRONIZER RING NO. 3 (for 6th Gear)
1. Check for wear or damage.
2. Coat the 6th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 6th gear cone. Check that the ring locks. If the synchronizer outer ring does not lock, replace the ring or the 6th gear.
  
  Fig 7: Inspecting Synchronizer Ring No.3 (For 6th Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
  Standard clearance:
  
  0.75 to 1.65 mm (0.0295 to 0.065 in.)
  
  If the clearance is out of specification, replace the synchronizer ring No. 3.
  
  Fig 8: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 6TH GEAR SUB-ASSEMBLY

Using a caliper gauge, measure the 6th gear inner diameter.

Inner diameter:

INNER DIAMETER

New gear: mm (in.)	Maximum inner diameter: mm (in.)
28.015 to 28.031 (1.1030 to 1.1036)	28.031 (1.1036)

Fig 9: Measuring 6th Gear Inner Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the clearance exceeds the maximum, replace the 6th gear sub-assembly.

INSPECT SYNCHRONIZER RING NO. 3 (for 5th Gear)
1. Coat the 5th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks. If the synchronizer outer ring does not lock, replace the ring or the 5th gear.
  
  Fig 10: Inspecting Synchronizer Ring No.3 (For 5th Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the synchronizer ring back and 5th gear spline end.
  Standard clearance:
  
  0.75 to 1.65 mm (0.0295 to 0.0650 in.)
  
  If the clearance is out of specification, replace the synchronizer ring No. 3.
  
  Fig 11: Measuring Clearance Between Synchronizer Ring Back And 5th Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR

Using a caliper gauge, measure the 5th gear inner diameter.

Inner diameter:

INNER DIAMETER

New gear: mm (in.)	Maximum inner diameter: mm (in.)
29.915 to 29.931 (1.1778 to 1.1784)	29.931 (1.1784)

If the inner diameter exceeds the maximum, replace the 5th gear.

Fig 12: Measuring 5th Gear Inner Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

Using a caliper gauge, inspect the reverse idler gear sub-assembly as shown in the illustration.

Inner diameter:

INNER DIAMETER

New gear: mm (in.)	Maximum inner diameter: mm (in.)
18.040 to 18.058 (0.7102 to 0.7109)	18.058 (0.7109)

If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assembly.

Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.

Outer diameter:

OUTER DIAMETER

New idler gear shaft: mm (in.)	Minimum outer diameter: mm (in.)
17.966 to 17.984 (0.7073 to 0.7080)	17.966 (0.7073)

If the outer diameter is less than the minimum, replace the reverse idler gear shaft.

Fig 13: Inspecting Reverse Idler Gear Sub-Assembly