Manual Transmission Unit Inspection
Drivetrain. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
INSPECT COUNTER 5TH GEAR THRUST CLEARANCE
INSPECT COUNTER 5TH GEAR RADIAL CLEARANCE
INSPECT NO. 3 SYNCHRONIZER RING
INSPECT NO. 3 TRANSMISSION HUB SLEEVE
INSPECT COUNTER 5TH GEAR
INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE
Manual Transmission Unit -- Inspection |
| 1. INSPECT COUNTER 5TH GEAR THRUST CLEARANCE |
Using a feeler gauge, measure the thrust clearance.
- Standard clearance:
- 0.10 to 0.35 mm (0.00394 to 0.0137 in.)
If the clearance is not as specified, replace the counter 5th gear.
| 2. INSPECT COUNTER 5TH GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the radial clearance.
- Standard clearance:
- 0.015 to 0.068 mm (0.00591 to 0.00267 in.)
If the clearance is not as specified, replace the counter 5th gear bearing with a new one.
| 3. INSPECT NO. 3 SYNCHRONIZER RING |
Apply gear oil to the cone part of the No. 5 gear spline piece, and check that it does not turn in either direction while pushing the No. 3 synchronizer ring against the No. 5 gear spline piece.
Text in Illustration*a
| Locks
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If it can turn, replace the No. 3 synchronizer ring.
Push the No. 3 synchronizer ring against the cone part of the No. 5 gear spline piece. Measure the clearance between the No. 3 synchronizer ring and No. 5 gear spline piece.
- Standard clearance:
- 0.68 to 1.32 mm (0.0268 to 0.0519 in.)
If the clearance is not as specified, replace the No. 3 synchronizer ring with a new one.
| 4. INSPECT NO. 3 TRANSMISSION HUB SLEEVE |
Check the sliding condition between the counter shaft 5th gear and No. 3 transmission hub sleeve.
Check the spline gear of the No. 3 transmission hub sleeve for wear.
If there are any defects, replace the No. 3 transmission hub sleeve.
Using a vernier caliper, measure the No. 3 transmission hub sleeve groove and the thickness of the claw part of the No. 3 shift fork to calculate the clearance.
- Standard clearance:
- 0.26 to 0.84 mm (0.0102 to 0.0330 in.)
If the clearance is not as specified, replace the No. 3 transmission hub sleeve and No. 3 shift fork with new ones.
| 5. INSPECT COUNTER 5TH GEAR |
Using a cylinder gauge, measure the inside diameter of the counter 5th gear.
- Standard inside diameter:
- 38.015 to 38.040 mm (1.4967 to 1.4976 in.)
- Maximum inside diameter:
- 38.040 mm (1.4976 in.)
If the inside diameter is more than the maximum, replace the counter shaft 5th gear with a new one.
| 6. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY |
Using a caliper gauge, measure the inside diameter of the reverse idler gear.
- Standard inside diameter:
- 24.040 to 24.061 mm (0.9465 to 0.9472 in.)
- Maximum inside diameter:
- 24.061 mm (0.9472 in.)
If the inside diameter is more than the maximum, replace the reverse idler gear with a new one.
Using a micrometer, measure the diameter of the sliding part of the reverse idler gear on the reverse idler gear shaft.
- Standard diameter:
- 23.979 to 24.000 mm (0.9441 to 0.9448 in.)
- Minimum diameter:
- 23.979 mm (0.9441 in.)
If the diameter is less than the minimum, replace the reverse idler gear shaft.
Using a feeler gauge, measure the thrust clearance of the shoe part between the reverse idler gear and reverse shift arm.
- Standard clearance:
- 0.05 to 0.35 mm (0.0020 to 0.0138 in.)
If the clearance is not as specified, replace the reverse idler gear and reverse shift arm.
| 7. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE |
Install the reverse idler gear to the reverse idler gear shaft, and clamp it in a vise.
Using a dial indicator, measure the radial clearance.
- Standard clearance:
- 0.040 to 0.082 mm (0.00157 to 0.00322 in.)
If the clearance is not as specified, replace the reverse idler gear.
