Input Shaft: 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 GEAR 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.
  
  Fig 1: Turning Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
4. Using a feeler gauge, measure the clearance between the synchronizer ring back and spline end.
  
  Fig 2: Measuring Clearance Between Synchronizer Ring Back And Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Minimum clearance:
  
  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.
MEASURE NO. 2 SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Fig 3: Measuring Clearance Between Hub Sleeve And Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Maximum clearance: 0.69 mm (0.0272 in.)

If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
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.
  
  Fig 4: Measuring Outer Diameter Of Input Shaft Journal Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Minimum outer diameter:
  
  Part A: 27.957 mm (1.1007 in.)
  
  Part B: 35.984 mm (1.4167 in.)
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