Transfer Case Input Shaft: Inspection

Remove the 2 oil seal rings.

1. Using a micrometer, measure the outer diameter of the input shaft journal surface.
   Fig 1: Identifying Outer Diameter Of Input Shaft Journal Surface For Inspection

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   Minimum diameter: 47.59 mm (1.8736 in.) 

2. Using a dial indicator, measure the inside diameter of the input shaft bushing.
   Fig 2: Measuring Inside Diameter Of Input Shaft Bushing

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   Maximum inside diameter: 39.14 mm (1.5409 in.) 

If the inside diameter exceeds the maximum, replace the input shaft.

Inspect Synchronizer Ring  .

1. Turn the ring and push it in to check the braking action.
   Fig 3: Checking Braking Action Of Synchronizer Ring - M/T

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2. Measure the clearance between the synchronizer ring back and the input shaft spline end.
   Fig 4: Measuring Clearance Between Synchronizer Ring Back And Input Shaft Spline End - M/T

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard clearance: 

   1.05 - 1.85 mm (0.0413 - 0.0728 in.) 

   Minimum clearance: 0.80 mm (0.0315 in.) 

If the clearance is less than the minimum, replace the synchronizer ring.

Install the 2 oil seal rings.