Manual Transaxle Unit: Inspection

INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, inspect the 5th gear thrust clearance.
  Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0256 in.)
  
  If clearance is out of specification, replace the No. 3 transmission clutch hub, 5th gear, or input shaft rear radial ball bearing.
  
  Fig 1: Inspecting 5Th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, inspect the 5th gear radial clearance.
  Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 in.)
  
  If clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing, or input shaft.
  
  Fig 2: Inspecting 5Th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

Using a caliper gauge, measure the inside diameter of the reverse idler gear.

Fig 3: Measuring Inside Diameter Of Reverse Idler Gear

G04977291

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inside diameter: mm (in.)

REVERSE IDLER GEAR INSIDE DIAMETER

Standard Inside diameter	Maximum Inside diameter
20.056 to 20.074 (0.7896 to 0.7903)	20.074 (0.7903)

If the inside diameter exceeds the maximum, replace the reverse idler gear.

Using a micrometer, measure the outside diameter of the reverse idler gear shaft.

Fig 4: Measuring Outside Diameter Of Reverse Idler Gear Shaft

G04977292

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Outside diameter: mm (in.)

REVERSE IDLER GEAR SHAFT OUTSIDE DIAMETER

Standard outside diameter	Minimum outside diameter
19.984 to 20.000 (0.7868 to 0.7874)	19.984 (0.7868)

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

INSPECT NO. 3 TRANSMISSION CLUTCH HUB
1. Inspect the sliding condition between the No. 3 transmission clutch hub and the No. 3 transmission hub sleeve.
  
  Fig 5: Inspecting Transmission Clutch Hub No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Inspect the tip of the spline gear on the No. 3 transmission hub sleeve for wear.
INSPECT NO. 3 TRANSMISSION HUB SLEEVE
1. Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove and the thickness of the claw part on the No. 3 gear shift fork, and calculate the clearance.
  Standard clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 in.) {A - B}
  
  If clearance is out of specification, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork with new ones.
  
  Fig 6: Measuring Width Of Transmission Hub Sleeve No. 3 Groove And Thickness Of Claw Part On Gear Shift Fork No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR

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

Fig 7: Measuring Inside Diameter Of 5Th Gear

G04977295

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Inside diameter mm (in.)

5TH GEAR INSIDE DIAMETER

Standard inside diameter	Maximum inside diameter
34.981 to 34.997 (1.3772 to 1.3778)	34.997 (1.3778)

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

INSPECT NO. 5 SYNCHRONIZER RING MIDDLE
1. Check that the No. 5 synchronizer ring middle rotates smoothly.
  
  Fig 8: Checking Synchronizer Ring Middle No. 5 Rotates Smoothly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the No. 5 synchronizer ring middle does not rotate while being pushed against the No. 3 clutch hub.
  
  Fig 9: Checking No. 5 Synchronizer Ring Middle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002