Output Shaft Assembly Inspection - Toyota Hilux Surf 1993 Owner's Manual

MANUAL TRANSMISSION –
INSPECTION OF OUTPUT SHAFT ASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of
each gear.
Standard clearance: 0.10 – 0.25 mm
Maximum clearance: 0.25 mm (0.0098 in.)
2. INSPECT EACH GEAR OIL CLEARANCE
Using a dial indicator, measure the each gear oil clear–
ance.
Standard clearance:
Maximum clearance:
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using calipers, measure the output shaft flange
thickness.
Minimum thickness: 4.80 mm (0.1890 in.)
If the thickness exceeds the minimum, replace the output
shaft.
(b) Using calipers, measure the inner race flange thick–
ness.
Minimum thickness: 3.99 mm (0.1571 in.)
If the thickness exceeds the minimum, replace the inner
race.
(c) Using a micrometer, measure the outer diameter of
Minimum diameter:
If the outer diameter exceeds the minimum, replace the
output shaft.
Component Parts (Output Shaft Assembly
(0.0039 – 0.0098 in.)
0.009 – 0.032 mm
(0.0004 – 0.0013 in.)
0.032 mm (0.0013 in.)
the output shaft journal.
2nd gear 37.984 mm (1.4954 in.)
3rd gear 34.984 mm (1.3773 in.)
MT1–43