a) Using a micrometer, measure the thickness of the secondary shaft edges.
- Minimum thickness - 4.70 mm
b) Using a micrometer, measure the outside diameter of the secondary shaft journals.
Minimum diameter:
- A - 38.860 mm
- B - 46.860 mm
- C - 37.860 mm
c) Using a digital indicator, check the runout of the secondary shaft.
- Maximum runout - 0.06 mm
2. Using a micrometer, measure the thickness of the intermediate shaft.
- Minimum diameter - 27.860 mm
3. Check the oil wedge of each gear.
Using a digital indicator, measure the oil wedge between the gear and the shaft with the roller bearing installed.
- Nominal clearance - 0.015 - 0.068 mm
- Maximum gap - 0.16 mm
If the gap is greater than the maximum, replace the gear, inner bearing ring and bearing.
4. Check the synchronizer rings.
a) By turning the synchronizer ring, check its friction properties.
b) Measure the gap between the synchronizer ring and the gear.
- Nominal clearance - 0.8 -1.6 mm
- Minimum gap - 0.6 mm
5. Using a feeler gauge, measure the gap between the gear shift forks and the synchronizer sleeves.
- Maximum gap - 1.0 mm
If the gap exceeds the maximum, replace the fork.
6. If necessary, replace the input shaft bearing.
a) Using round-nose pliers, remove the retaining ring.
b) Using a press, remove the bearing and install a new bearing.
c) Select a retaining ring to ensure minimum axial play and install it on the shaft.
7. If necessary, replace the front bearing housing oil seal.
a) Using a screwdriver, remove the seal.
b) Using a tool head, press in a new oil seal.
- Seal installation depth: 11.2-12.2 mm
8. If necessary, replace the front intermediate shaft bearing.
a) Using round-nose pliers, remove the retaining ring.
b) Using a vice and a tool head, remove the bearing and replace it.
c) Select a retaining ring to ensure minimum axial play and install it on the shaft.
9. If necessary, replace the speedometer drive gear oil seal.
a) Using a special tool, remove the oil seal.
b) Using a tool head, insert a new oil seal.
- Pressing depth - 25 mm
10. If necessary, replace the gear selector lever seal.
a) Using a screwdriver, remove the seal.
b) Using a 14mm socket and hammer, press in the new seal.
11. If necessary, replace the gear shift lever seal.
a) Using a screwdriver, remove the seal.
b) Using a 21mm socket and hammer, press in the new seal.
12. If necessary, replace the extension housing seal.
The publication is taken from the website www.toyotaman.ru
Using a special tool, remove and install a new oil seal.