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Input Shaft: Inspection

  1. INSPECT 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. Check again the braking effect of the synchronizer ring.
      Fig 1: Inspecting Synchronizer Ring
      G02631400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

    Minimum clearance: 

    3RD AND 4TH GEAR - MINIMUM CLEARANCE TABLE

    3rd gear 0.65 mm (0.0256 in.)
    4th gear 0.75 mm (0.0295 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 And Gear Spline End
    G02631401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT NO. 2 GEAR SHIFT FORK AND NO. 2 HUB SLEEVE CLEARANCE 

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

    Maximum clearance: 0.35 mm (0.014 in.) 

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

    Fig 3: Measuring Clearance Between Hub Sleeve And Gear Shift Fork
    G02631402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT INPUT SHAFT 
    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: 

      MINIMUM OUTER DIAMETER TABLE

      Part A (5th gear) 24.885 mm (0.9797 in.)
      Part B (4th gear) 28.985 mm(1,1411 in.)
      Part C (3rd gear) 30.985 mm (1.2199 in.)
      Part D (Roller bearing) 24.985 mm (0.9837 in.)

      If the outer diameter is less than the minimum, replace the input shaft.

      Fig 4: Inspecting Input Shaft
      G02631403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a dial indicator, check the shaft runout.

      Maximum runout: 0.03 mm (0.0012 in.) 

      If the runout exceeds the maximum, replace the input shaft.

      Fig 5: Checking Shaft Runout Using A Dial Indicator
      G02631404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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