Important: When you service the synchronizers, retain
them in the order that they are removed. Mark the parts to ensure the correct position
for inspection and assembly.
- Clean all the synchronizer parts in a suitable cleaning solvent and air dry
all the parts.
- Inspect the 1st/2nd gear and the 3rd/4th gear synchronizer hubs for a
force fit on the output shaft.
- 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 (1), due to wear, may cause shift concerns.
- 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. |
- Inspect the synchronizer sleeve teeth (1) for
the following conditions, which may cause shift concerns:
- Inspect the synchronizer sleeve detent stops (2) for wear or for
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 (1).
- Replace the blocker ring assembly if the blocker ring grooves are worn.
- Inspect the synchronizer blocker rings for worn shift
teeth (1).
- Inspect the internal ring for being warped or damaged.
- Inspect the outer ring for worn grooves.
- Replace the synchronizer assembly for any of the above conditions.
- Install the synchronizer blocking rings to the correct
speed gear.
- Inspect the braking effect of the blocking ring. Turn the blocking ring
in one direction while pushing to the gear cone. Ensure the ring locks.
- If the ring does not lock, replace the synchronizer assembly.
- Except for 5th gear, measure the blocker ring to gear
clearance.
| 19.1. | Assemble the correct blocker ring to the correct gear. |
| 19.2. | Apply pressure to the blocker ring to fully seat the ring. |
| 19.3. | Using a feeler gage, measure between the blocker ring teeth and the teeth
on the gear. |
Specification
| • | Minimum Clearance 4th Gear: 0.8 mm (0.031 in) |
| • | Minimum Clearance 3rd Gear: 0.8 mm (0.031 in) |
| • | Minimum Clearance 2nd Gear: 0.8 mm (0.031 in) |
| • | Minimum Clearance 1st Gear: 0.8 mm (0.031 in) |
- If using a NEW blocker ring and the standard clearance can not be obtained,
replace the gear.
- Inspect the pressure pieces (2) for wear or
damage.
- Inspect the springs (1) for distortion.
- Replace the worn pressure pieces or faulty springs.
