Output Shaft Inspection

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.20 to 0.45 mm (0.00789 to 0.0177 in.)

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.020 to 0.073 mm (0.00078 to 0.00287 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.000598 to 0.00267 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.00059 to 0.00267 in.)

Using a dial indicator, measure the output shaft at point A, B and C shown in the illustration, and measure the runout of the output shaft.

Maximum runout:

0.03 mm (0.00118 in.)

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

Standard Outside Diameter:

Item	Specified Condition
Journal A	38.979 to 38.995 mm (1.5346 to 1.5340 in.)
Journal B	46.984 to 47.000 mm (1.8498 to 1.8503 in.)
Journal C	37.984 to 38.000 mm (1.4955 to 1.4960 in.)

Using a micrometer, measure the thickness of the output shaft flange as shown in the illustration.

Standard thickness:

4.8 to 5.2 mm (0.1890 to 0.2047 in.)

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

Standard inside diameter:

44.015 to 44.040 mm (1.7329 to 1.7338 in.)

Maximum inside diameter:

44.040 mm (1.7338 in.)

Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Standard inside diameter:

53.015 to 53.040 mm (2.0872 to 2.0881 in.)

Maximum inside diameter:

53.040 mm (2.0881 in.)

Using a cylinder gauge, measure the inside diameter of the 1st gear.

Standard inside diameter:

46.015 to 46.040 mm (1.8117 to 1.8125 in.)

Maximum inside diameter:

46.040 mm (1.8125 in.)

Using a micrometer, measure the thickness of the thrust washer.

Standard thickness:

5.95 to 6.05 mm (0.235 to 0.238 in.)

Minimum thickness:

5.95 mm (0.235 in.)

Apply gear oil to the cone of the 1st gear, and check that it does not turn in either direction while pushing the No. 1 synchronizer ring set.

Measure the clearance between the No. 1 synchronizer ring and 1st gear while pushing the No. 1 synchronizer ring against the cone of the 1st gear.

Standard clearance:

for TR Engine series:

0.75 to 1.65 mm (0.0296 to 0.0649 in.)

for 1KD-FTV, 2KD-FTV:

0.65 to 1.75 mm (0.0256 to 0.0688 in.)

Apply gear oil to the cone of the 2nd gear, and check that it does not turn in both directions while pushing the No. 1 synchronizer ring set.

Push the No. 1 synchronizer ring set against the cone of the 2nd gear. Measure the clearance between the No. 1 synchronizer ring set and 2nd gear.

Standard clearance:

0.65 to 1.75 mm (0.0256 to 0.0688 in.)

Apply gear oil to the cone of the 3rd gear, and check that it does not turn in either direction while pushing the No. 2 synchronizer ring (for the 3rd gear).

Push the No. 2 synchronizer ring against the cone of the 3rd gear. Measure the clearance between the No. 2 synchronizer ring (for the 3rd gear) and 3rd gear.

Standard clearance:

0.75 to 1.65 mm (0.0296 to 0.0649 in.)

Using a vernier caliper, measure the reverse gear groove and the thickness of the claw of the No. 1 shift fork to calculate the clearance.

Standard clearance:

0.15 to 0.41 mm (0.00591 to 0.0161 in.)

Check the sliding condition between the No. 1 clutch hub and the reverse gear.

Check the spline gear sleeve of the reverse gear for wear.
If there are any defects, replace the No. 1 clutch hub.

Using a vernier caliper, measure the No. 2 hub sleeve groove and the thickness of the claw of the No. 2 shift fork.

Standard clearance:

0.15 to 0.35 mm (0.00591 to 0.0137 in.)

Check the sliding condition between the No. 2 clutch hub and No. 2 hub sleeve.

Check the spline gear of the No. 2 hub sleeve for wear.