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.

   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

   Courtesy 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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. 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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Minimum journal diameter: 

   MINIMUM JOURNAL DIAMETER TABLE
   
   

   Part A	21.991 mm (0.8658 in.)
   Part B	24.885 mm (0.9797 in.)
   Part C	28.991 mm (1.1414 in.)
   Part D	30.985 mm (1.2199 in.)
   Part E	24.985 mm (0.9837 in.)

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

   Fig 4: Inspecting Input Shaft

   Courtesy 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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002