Transfer Assembly: Inspection

CHECK TRANSFER INPUT SHAFT
1. Using a micrometer, measure the diameter of the input shaft journal surface.
  Minimum diameter: 47.59 mm (1.8736 in.)
  
  If the diameter is less than the minimum, replace the input shaft.
  
  Fig 1: Measuring Diameter Of Input Shaft Journal Surface Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the inside diameter of the input shaft bushing.
  Maximum inside diameter: 39.14 mm (1.5409 in.)
  
  If the inside diameter is greater than the maximum, replace the input shaft.
  
  Fig 2: Measuring Inside Diameter Of Input Shaft Bushing Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PLANETARY PINION GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the thrust clearance of the pinion gear.
  Standard clearance: 0.11 to 0.84 mm (0.0043 to 0.0331 in.)
  
  Maximum clearance: 0.84 mm (0.0331 in.)
  
  If the clearance is greater than the maximum, replace the low planetary gear.
  
  Fig 3: Measuring Thrust Clearance Of Pinion Gear Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PLANETARY PINION GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the radial clearance of the pinion gear.
  Standard clearance: 0.009 to 0.038 mm (0.0004 to 0.0015 in.)
  
  Maximum clearance: 0.038 mm (0.0015 in.)
  
  If the clearance is greater than the maximum, replace the low planetary gear.
  
  Fig 4: Measuring Radial Clearance Of Pinion Gear Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK TRANSFER DRIVE SPROCKET THRUST CLEARANCE
1. Using a feeler gauge, measure the thrust clearance.
  Standard clearance: 0.10 to 0.25 mm (0.0039 to 0.0098 in.)
  
  Maximum clearance: 0.25 mm (0.0098 in.)
  
  If the thrust clearance is greater than the maximum, replace the driver sprocket.
  
  Fig 5: Measuring Thrust Clearance Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK REAR TRANSFER OUTPUT SHAFT
1. Using a micrometer, measure the diameter of the output shaft journal surface.
  Minimum diameter: 27.98 mm (1.1016 in.) for part A 36.98 mm (1.4561 in.) for part B
  
  If the diameter is less than the minimum, replace the output shaft.
  
  Fig 6: Measuring Diameter Of Output Shaft Journal Surface Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK TRANSFER DRIVE SPROCKET RADIAL CLEARANCE
1. Using a dial indicator, measure the radial clearance between the drive sprocket and output shaft with the needle roller bearing installed.
  Standard radial clearance: 0.010 to 0.055 mm (0.0004 to 0.0022 in.)
  
  Maximum radial clearance: 0.055 mm (0.0022 in.)
  
  If the radial clearance is greater than the maximum, replace the drive sprocket or needle roller bearing.
  
  Fig 7: Measuring Radial Clearance Between Drive Sprocket & Output Shaft Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK TRANSFER HIGH AND LOW CLUTCH SLEEVE AND NO. 2 TRANSFER GEAR SHIFT FORK CLEARANCE
1. Using a feeler gauge, measure the clearance between the clutch sleeve and No. 2 gear shift fork.
  Maximum clearance: 1.0 mm (0.039 in.)
  
  If the clearance is greater than the maximum, replace the clutch sleeve or No. 2 gear shift fork.
  
  Fig 8: Measuring Clearance Between Clutch Sleeve & No. 2 Gear Shift Fork Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FRONT DRIVE CLUTCH SLEEVE AND NO. 1 TRANSFER GEAR SHIFT FORK CLEARANCE
1. Using a feeler gauge, measure the clearance between the clutch sleeve and No. 1 gear shift fork.
  Maximum clearance: 1.0 mm (0.039 in.)
  
  If the clearance is greater than the maximum, replace the clutch sleeve or No. 1 gear shift fork.
  
  Fig 9: Measuring Clearance Between Clutch Sleeve & No. 1 Gear Shift Fork Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002