Important: Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid. If a synchro body assembly has been completely disassembled then the following method of procedure shall be
observed for assembly.
- Assemble synchro body.
| • | Insert synchro body (1) into shift sleeve (2) |
| | Important: Position at an angle and then press into the synchro body assembly.
|
| • | Insert 3x thrust piece (3) |
- Fit needle bearing (1).
Place 2x slotted needle bearing on main shaft and clip together.
Important: Synchronizer ring lugs must be aligned with synchro body grooves.
- Attach synchro body assembly 3rd/4th gear.
| • | Position 4th gear synchro ring (3) and synchro body assembly (2) on 4th gear (4) |
| | Important: Groove on slider sleeve (arrow) points to 4th gear.
|
| • | Press synchro body assembly (6) and 4th gear (5) on to main shaft |
- Fit 3rd gear.
| • | Locate spacing ring on synchro body |
| | Important: Use new retaining ring.
|
| • | Attach retaining ring with
KM-396
(3) - Retaining ring must sit in groove correctly |
| • | Locate synchronizer ring 3rd gear (2) on synchro body assembly |
| • | Attach 2x slotted needle bearings (1) to main shaft |
| • | Locate 3rd gear (5) on main shaft |
| • | Fit both halves of the thrust washer (arrows) and retaining ring (4) using grease |
Important: Lugs of the synchro rings must be flush with the grooves of the synchro body and the gear wheel.
- Attach synchro body assembly 1st/2nd gear.
| • | Place needle bearing on main shaft |
| • | Locate synchro body 1st/2nd gear (6) with inner synchro ring (9), intermediate ring (8) and outer synchro ring (7) on gear wheel for 2nd gear (10) |
| • | Press synchro body assembly 1st/2nd gear (12) on to main shaft with 2nd gear (11) |
- Secure synchro body assembly 1st/2nd gear (3).
Important: Retaining ring must sit in groove correctly.
- Insert new retaining ring (1) using
KM-396
(2).
- Attach 1st gear (5).
| • | Locate slotted needle bearing (6) on main shaft |
| | Important: Lugs of the synchro rings must be flush with the grooves of the synchro body and the gear wheel.
|
| • | Locate 1st gear with inner synchro ring (9), intermediate ring (8) and outer synchro ring (7) on synchro body assembly 1st/2nd gear (10) |
- Fit thrust washer 1st gear (4).
Press thrust washer onto main shaft (11) using
KM-307-B
.
- Visually check main shaft. All gears must turn freely.
