Transfer Assembly: Inspection

INSPECT TRANSFER INPUT SHAFT
1. Using a micrometer, measure the diameter of the input shaft journal surface.
  Minimum Diameter:
  
  68 mm (2.68 in.)
  
  If the diameter is less than the minimum, replace the input shaft.
  
  Fig 1: Inspecting Transfer Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the inside diameter of the input shaft bush.
  Maximum Inside Diameter:
  
  46 mm (1.81 in.)
  
  If the inside diameter is more than the maximum, replace the input shaft.
  
  Fig 2: Measuring Inside Diameter Of Input Shaft Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY
1. Using a feeler gauge, measure the thrust clearance of the pinion gear.
  Standard Clearance:
  
  0.11 to 0.85 mm (0.00434 to 0.0334 in.)
  
  Maximum Clearance:
  
  0.85 mm (0.0334 in.)
  
  If the clearance is more than the maximum, replace the low planetary gear assembly.
  
  Fig 3: Measuring Thrust Clearance Of Pinion Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the radial clearance of the pinion gear.
  Standard Clearance:
  
  0.01 to 0.04 mm (0.000434 to 0.00150 in.)
  
  Maximum Clearance:
  
  0.04 mm (0.00150 in.)
  
  If the clearance is more than the maximum, replace the low planetary gear assembly.
  
  Fig 4: Measuring Radial Clearance Of Pinion Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT REAR TRANSFER OUTPUT SHAFT

Using a micrometer, measure the diameter of the output shaft journals.

Minimum Diameter

JOURNAL SPECIFIED CONDITION

Journal	Specified Condition
A	38 mm (1.50 in.)
B	42 mm (1.65 in.)
C	49 mm (1.93 in.)

If the diameter is less than the minimum, replace the output shaft.

Fig 5: Inspecting Rear Transfer Output Shaft

INSPECT NO. 1 TRANSFER GEAR SHIFT FORK AND FRONT DRIVE CLUTCH SLEEVE
1. Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.
  Maximum Clearance:
  
  0.8 mm (0.0315 in.)
  
  If the clearance is more than the maximum, replace the clutch sleeve or shift fork.
  
  Fig 6: Measuring Clearance Between Clutch Sleeve And Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT AND ADJUST NO. 2 TRANSFER GEAR SHIFT FORK AND HIGH AND LOW CLUTCH SLEEVE
1. Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.
  Maximum Clearance:
  
  3.15 mm (0.124 in.)
  
  If the clearance is more than the maximum, replace the clutch sleeve or shift fork.
  
  Fig 7: Measuring Clearance Between Clutch Sleeve And Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 SYNCHRONIZER RING
1. Apply gear oil to the cone of the input shaft, and check that it does not turn in both directions while pushing the No. 1 synchronizer ring.
  If it can turn, replace the No. 1 synchronizer ring.
  
  Fig 8: Inspecting Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Push the No. 1 synchronizer ring to the cone of the input shaft. Measure the clearance between the No. 1 synchronizer ring and input shaft.
  Standard Clearance:
  
  0.86 to 1.54 mm (0.0339 to 0.0606 in.)
  
  Minimum Clearance:
  
  0.86 mm (0.0339 in.)
  
  If the clearance is less than the minimum, replace the No. 1 synchronizer ring with a new one.
  
  Fig 9: Measuring Clearance Between Synchronizer Ring And Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002