- Clean all the synchronizer parts in a suitable solvent. Air dry all the
synchronizer parts.
- Inspect the synchronizer parts for the following conditions:
| • | Chamfer for excessive wear |
| • | Free movement of the clutching sleeves on their hubs |
| • | Worn or damaged clutch teeth |
Important: Replace a burred or nicked part that cannot
be reconditioned by hand.
- Replace synchronizer parts that are worn or damaged.
- Measure the gap between the vertical faces of the
blocking ring teeth and the speed gear as follows:
| 4.1. | Assemble the correct blocking ring with the correct speed gear. |
| 4.2. | The blocking ring must be fully seated on the gear. |
| 4.3. | Use a feeler gauge to measure the forward gear gap. |
| 4.4. | Use a feeler gauge to measure the reverse gear gap. |
Measure
the gap without the wave washer in between the blocking ring and the reverse gear.
The nominal gap is 1.27-2.16 mm (0.050-0.085 in) for
the 1st and 2nd gear.
The nominal gap is 1.27-2.03 mm (0.050-0.080 in) for
the 3rd, 4th, 5th and 6th gear.
Replace the friction cones and blocker rings when the gap is significantly less
than specified.
