An animal exposure experiment which simulated a workplace exposure situation was made to compare toluene diisocyanate (TDI) concentrations which resulted in antibody production with those which elicited pulmonary responses. Groups of guinea pigs were exposed to inhaled TDI from 0.02 to 1.0 ppm (p.g/g) for 3 h/day on 5 consecutive days. Three weeks later the animals were challenged with 0.02 ppm of free TDI for 15 min. TDI specific antibodies and pulmonary responses were evaluated. Specific antibody production showed a linear correlation to TDI concentration at induction. Most of the animals exposed to TDI levels above 0.2 ppm displayed significant pulmonary responses, but no correlation was found between TDI concentration at induction and the intensity of pup monary response upon challenge to free TDI. These results indicated that there was a threshold concentration of 0.02 ppm TDI for antibody production and for the development of pulmonary response. It was also found that exposure to TDI at a level lower than its threshold concentration for sensitization may elicit a response in previously sensitized individuals.