Important: When you service the synchronizers, retain them in the same order that
they are removed. Mark the parts to ensure the correct position for inspection
and assembly.
- Clean all the parts in a suitable cleaning solvent and air dry.
- Inspect the 2nd/3rd, 4th/5th synchronizer hubs for a force fit
on the mainshaft.
The 6th gear synchronizer hub and the 1st/reverse
gear synchronizer hub are slip fit.
- Replace synchronizer hubs that do not require a force fit.
- Inspect the synchronizer hub for wear on the external splines.
A stepped effect on the teeth, due to wear, may cause shift conditions.
- Replace a worn hub.
- Correct the cause, such as, but not limited to the following conditions:
| • | Engine related vibrations |
| • | Driving at a low speed in a high gear |
| • | Defective vibration damper or crankshaft |
| • | Incorrectly set injector pump |
- Inspect the synchronizer
sleeve teeth (1) for the following, which may cause shift conditions:
- Inspect the synchronizer sleeve detent stops (2) for wear
or being chipped off.
- Replace the synchronizer assembly if the teeth or stops show the
above conditions.
- Inspect the synchronizer
blocker rings for worn away grooves.
- Replace the blocker ring assembly if the blocker ring grooves
are worn away.
- Inspect the synchronizer
blocker rings for worn shift teeth.
- Inspect the middle ring for being warped or damaged.
- Inspect the outer ring for worn grooves.
- Replace the synchronizer assembly if any of the above conditions
are found.
- Measure the blocker ring
to gear clearance.
| 16.1. | Assemble the correct blocker ring to the correct gear. |
| 16.2. | Apply pressure to the blocker ring to fully seat the ring. |
| 16.3. | Using a feeler gage, measure between the blocker ring teeth and
the teeth on the gear. |
| • | Synchronizer Reserve - New Gear, New Ring 2nd/3rd, Dual
Cone, clearance between the blocker ring and the gear is 1.5-0.1.85 mm
(0.059-0.073 in). |
| • | Synchronizer Reserve - New Gear, New Ring 4th, 5th, 6th,
1st, and reverse between the blocker ring and the gear is 1.4-1.7 mm
(0.055-0.067 in). |
- Gear clash occurs around reserve 1.0 mm (0.039 in)
or less.
If using a NEW blocker ring and the standard clearance
can not be obtained, replace the gear.
- Inspect the pressure pieces for wear or damage.
- Inspect the springs for distortion.
Important: When you service the synchronizers, retain them in the same order
they are removed. Mark the parts to ensure the correct position for inspection
and assembly.
- Clean all the parts in a suitable cleaning solvent. Air dry all the
parts.
- Inspect the 2nd/3rd, 4th/5th, synchronizer hubs for a force fit
on the mainshaft.
The 6th gear synchronizer hub and the 1st/reverse
gear synchronizer hub are slip fit.
- Replace synchronizer hubs that do not require a force fit.
- Inspect the synchronizer hub for wear on the external splines.
A stepped effect on the teeth, due to wear, may cause shift problems.
- Replace a worn hub.
- Correct the cause such as, but not limited to the following:
| • | Engine related vibrations |
| • | Driving at a low speed in a high gear |
| • | Defective vibration damper or crankshaft |
| • | Incorrectly set injector pump |
- Inspect the synchronizer
sleeve teeth (1) for the following which may cause shift problems:
- Inspect the synchronizer sleeve detent stops (2) for wear
or being chipped off.
- Replace the synchronizer assembly if the teeth or stops show the
above conditions.
- Inspect the synchronizer
blocker rings for worn away grooves.
- Replace the blocker ring assembly if the blocker ring grooves
are worn away.
- Inspect the synchronizer
blocker rings for worn shift teeth.
- Inspect the middle ring for being warped or damaged.
- Inspect the outer ring for worn grooves.
- Replace the synchronizer assembly for any of the above conditions.
- Measure the blocker ring
to gear clearance.
| 16.1. | Assemble the correct blocker ring to the correct gear. |
| 16.2. | Apply pressure to the blocker ring to fully seat the ring. |
| 16.3. | Using a feeler gage, measure between the blocker ring teeth and
the teeth on the gear. |
| • | Synchronizer Reserve - New Gear, New Ring 2nd/3rd, Dual Cone,
clearance between the blocker ring and the gear is 1.5-0.1.85 mm
(0.059-0.073 in). |
| • | Synchronizer Reserve - New Gear, New Ring 4th, 5th, 6th, 1st,
and reverse between the blocker ring and the gear is 1.4-1.7 mm
(0.055-0.067 in). |
- Gear clash will occur around reserve 1.0 mm (0.039 in)
or less.
If using a NEW blocker ring and the standard clearance
can not be obtained, replace the gear.
- Inspect the pressure pieces for wear or damage.
- Inspect the springs for distortion.
