Toyota Tacoma manuals

Toyota Tacoma 2015-2018 Service Manual: Inspection

INSPECTION

PROCEDURE

1. INSPECT INPUT SHAFT

(a) Using a dial indicator and 2 V-blocks, measure the shaft runout.

Maximum runout:

0.03 mm (0.0012 in.)

If the runout is more than the maximum, replace the input shaft.

HINT:

Measure the 3 areas shown in the illustration with the input shaft level.

(b) Using a micrometer, measure the journal diameter of each input shaft journal at the specified positions.

Standard Journal Diameter:

Item

Specified Condition

Journal A

34.009 to 34.022 mm (1.3390 to 1.3394 in.)

Journal B

44.985 to 45.000 mm (1.7711 to 1.7716 in.)

Journal C

44.985 to 45.000 mm (1.7711 to 1.7716 in.)

Journal D

41.985 to 42.000 mm (1.6530 to 1.6535 in.)

Journal E

32.967 to 32.98 mm (1.2980 to 1.2984 in.)

Minimum Diameter:

Item

Specified Condition

Journal A

34.009 mm (1.3389 in.)

Journal B

44.985 mm (1.7711 in.)

Journal C

44.985 mm (1.7711 in.)

Journal D

41.985 mm (1.6530 in.)

Journal E

32.967 mm (1.2980 in.)

If the journal diameter is less than the minimum, replace the input shaft.

2. INSPECT 5TH GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 5th gear.

Standard inside diameter:

53.013 to 53.029 mm (2.0872 to 2.0877 in.)

Maximum inside diameter:

53.029 mm (2.0877 in.)

If the inside diameter is more than the maximum, replace the 5th gear.

3. INSPECT 6TH GEAR SUB-ASSEMBLY

(a) Using a cylinder gauge, measure the inside diameter of the 6th gear sub-assembly.

Standard inside diameter:

51.015 to 51.040 mm (2.0085 to 2.0094 in.)

Maximum inside diameter:

51.040 mm (2.0094 in.)

If the inside diameter is more than the maximum, replace the 6th gear sub-assembly.

4. INSPECT 3RD GEAR

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

Standard inside diameter:

51.015 to 51.040 mm (2.0085 to 2.0094 in.)

Maximum inside diameter:

51.040 mm (2.0094 in.)

If the inside diameter is more than the maximum, replace the 3rd gear.

5. INSPECT NO. 2 TRANSMISSION HUB SLEEVE

(a) Check the sliding condition between the No. 2 transmission hub and No. 2 transmission hub sleeve.

(b) Check that the splines of the No. 2 transmission hub sleeve are not worn.

(c) Using a vernier caliper, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part of the No. 2 or No. 3 gear shift forks (B), and calculate the clearance.

Standard Clearance (A - B):

Item

Specified Condition

No. 2 gear shift fork

0.28 to 0.84 mm (0.0111 to 0.0331 in.)

No. 3 gear shift fork

0.28 to 0.84 mm (0.0111 to 0.0331 in.)

If the clearance is outside the specification, replace the No. 2 transmission hub sleeve and gear shift fork.

6. INSPECT NO. 3 SYNCHRONIZER RING (for 5th Gear)

(a) Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring and 5th gear.

Standard clearance:

0.77 to 1.63 mm (0.0304 to 0.0641 in.)

Minimum clearance:

0.77 mm (0.0304 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

(b) Coat the 5th gear cone with gear oil.

(c) Check the braking effect of the synchronizer ring.

(1) Turn the synchronizer ring in both directions while pushing it against the 5th gear cone. Check that the ring locks in both directions. If the No. 3 synchronizer ring turns, replace it.

7. INSPECT NO. 3 SYNCHRONIZER RING (for 6th Gear)

(a) Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring and 6th gear.

Standard clearance:

0.77 to 1.63 mm (0.0304 to 0.0641 in.)

Minimum clearance:

0.77 mm (0.0304 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

(b) Coat the 6th gear cone with gear oil.

(c) Check the braking effect of the synchronizer ring.

(1) Turn the synchronizer ring in both directions while pushing it against the 6th gear cone. Check that the ring locks in both directions. If the No. 3 synchronizer ring turns, replace it.

8. INSPECT NO. 3 SYNCHRONIZER RING SET

(a) Using a feeler gauge, measure the clearance between the synchronizer ring and 3rd gear.

Standard clearance:

0.86 to 2.02 mm (0.0339 to 0.0795 in.)

Minimum clearance:

0.86 mm (0.0339 in.)

If the clearance is less than the minimum, replace the No. 3 synchronizer ring set.

(b) Coat the 3rd gear cone with gear oil.

(c) Check the braking effect of the synchronizer ring.

(1) Turn the synchronizer ring in both directions while pushing it against the 3rd gear cone. Check that the ring locks in both directions. If the No. 3 synchronizer ring set turns, replace it.

9. INSPECT 3RD GEAR THRUST WASHER

(a) Using a micrometer, measure the 3rd gear thrust washer thickness.

Standard thickness:

7.62 to 7.68 mm (0.3000 to 0.3023 in.)

Minimum thickness:

7.62 mm (0.3000 in.)

If the thickness is less than the minimum, replace the 3rd gear thrust washer.

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