Manual Transaxle Assembly: 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.

   NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
   Fig 1: Turning Synchronizer Ring

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3. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

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

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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: Measuring Clearance Between Hub Sleeve & Shift Fork

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002