Manual Transaxle Assembly: Inspection

WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT NO. 5 SYNCHRONIZER RING
1. Check for wear or damage.
2. Check the braking effect of the synchronizer ring.
  Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
  
  If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
  
  NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
3. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
  
  Fig 2: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Minimum clearance: 0.7 mm (0.028 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.
  
  NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
INSPECT NO. 3 SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 0.35 mm (0.014 in.)

If the clearance exceeds the maximum, replace the shift fork or hub sleeve.

Fig 3: Inspecting No. 3 Shift Fork & Hub Sleeve Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002