Toyota Tundra. Manual — part 2930

Fig. 58: Identifying No. 1 Synchromesh Shifting Key Springs
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION

1. INSPECT TRANSFER INPUT SHAFT

a. 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. 59: Measuring Diameter Of Input Shaft Journal Surface
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. 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 greater than the maximum, replace the input shaft.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra

Fig. 60: Measuring Inside Diameter Of Input Shaft Bush
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY

a. Using a feeler gauge, measure the thrust clearance of the pinion gear.

Standard clearance: 0.11 to 0.85 mm (0.00437 to 0.0335 in.)

Maximum clearance: 0.85 mm (0.0335 in.)

If the clearance is greater than the maximum, replace the low planetary gear assembly.

Fig. 61: Measuring Thrust Clearance Of Pinion Gear
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY

a. Using a dial indicator, measure the radial clearance of the pinion gear.

Standard clearance: 0.011 to 0.038 mm (0.000354 to 0.00150 in.)

Maximum clearance: 0.038 mm (0.00150 in.)

If the clearance is greater than the maximum, replace the low planetary gear assembly.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra

Fig. 62: Measuring Radial Clearance Of Pinion Gear
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. INSPECT REAR TRANSFER OUTPUT SHAFT

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

Minimum diameter

REAR TRANSFER OUTPUT SHAFT SPECIFIED CONDITION

Fig. 63: Identifying Output Shaft Journal
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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

5. INSPECT NO. 1 TRANSFER GEAR SHIFT FORK AND HUB SLEEVE

a. Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.

Maximum clearance: 2.1 mm (0.0827 in.)

If the clearance is greater than the maximum, replace the clutch sleeve or shift fork.

Journal Specified Condition

A

40 mm (1.58 in.)

B

49 mm (1.93 in.)

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra

Fig. 64: Measuring Clearance Between Clutch Sleeve And Gear Shift Fork
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

6. INSPECT NO. 2 TRANSFER GEAR SHIFT FORK AND HUB SLEEVE

a. Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.

Maximum clearance: 1.0 mm (0.0394 in.)

If the clearance is greater than the maximum, replace the clutch sleeve or shift fork.

Fig. 65: Measuring Clearance Between Clutch Sleeve And Gear Shift Fork
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REASSEMBLY

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL TRANSFER DRIVE CLUTCH HUB

a. Using SST and a press, press in the drive clutch hub.

SST 09513-36040

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra