Input Shaft: Inspection

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.

   Fig 1: Inspecting Gear Synchronizer Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
3. Check again the braking effect of the synchronizer ring.
4. Using a feeler gauge, measure the clearance between the synchronizer ring back and spline end.

   Minimum clearance: 

   3rd gear: 0.65 mm (0.0256 in.) 

   4th gear: 0.75 mm (0.0295 in.) 

   Fig 2: Measuring Clearance Between Synchronizer Ring Back & Spline End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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.

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

Maximum clearance: 0.69 mm (0.0272 in.) 

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

Fig 3: Measuring Clearance Between Hub Sleeve & Shift Fork

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the input shaft for wear or damage.
2. Using a micrometer, measure the outer diameter of the input shaft journal surface.

   Minimum outer diameter: 

   Part A: 27.957 mm (1.1007 in.) 

   Part B: 35.984 mm (1.4167 in.) 

   Fig 4: Measuring Outer Diameter Of Input Shaft Journal Surface

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a dial indicator, check the shaft runout.

   Maximum runout: 0.03 mm (0.0012 in.) 

   Fig 5: Checking Shaft Runout

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002