6. Synchronizers Disassemble
SYNCHRONIZERS DISASSEMBLE3rd/4th Synchronizers Disassemble
Important:
^ When you service the synchronizers, keep them in the order that they are removed.
^ Only remove the synchronizer sleeve from the hub if necessary. Re-assembly of the balls and springs may take some practice.
1. Mark the blocking rings in order for a correct assembly.
2. Remove the blocking rings.
3. Cover the 3rd/4th synchronizer with a shop towel to prevent loss of springs, the balls, and the inserts.
4. Remove the synchronizer sleeve from the synchronizer hub.
5. Remove the balls, the springs, and the inserts.
1st/2nd Synchronizers Disassemble
Important:
^ When you service the synchronizers, keep them in the order that they are removed.
^ Only remove the synchronizer sleeve from the hub if necessary. Re-assembly of the balls and springs may take some practice.
1. Remove the following synchronizer blocking rings from the 1st/2nd synchronizer assembly.
^ Blocking rings
^ Center rings
^ Inner rings
2. Cover the 1st/2nd synchronizer with a shop towel to prevent loss of springs, the balls, and the inserts.
3. Remove the synchronizer sleeve from the synchronizer hub.
4. Remove the shift balls, the springs, and the inserts.
5th/Reverse Synchronizers Disassemble
Important:
^ When you service the synchronizers, keep them in the order that they are removed.
^ Only remove the synchronizer sleeve from the hub if necessary. Re-assembly of the balls and springs may take some practice.
1. Mark the blocking rings in order for a correct assembly.
2. Remove the blocking rings.
3. Cover the 5th/reverse synchronizer with a shop towel to prevent loss of springs, the balls, and the inserts.
4. Remove the synchronizer sleeve from the synchronizer hub.
5. Remove the balls, the springs, and the inserts.
SYNCHRONIZERS CLEANING AND INSPECTION
Important: When you service the synchronizers, keep them in the order that they are removed.
1. Clean all the parts in a suitable cleaning solvent. Air dry all the parts.
2. Inspect the 1st/2nd and the 3rd/4th synchronizer hubs for a loose fit on the mainshaft.
3. Replace synchronizer hubs that are loose on the mainshaft.
4. Inspect the synchronizer hub for wear on the external splines. A stepped effect on the teeth due to wear may cause shift problems.
5. Replace a worn hub.
6. 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
7. Inspect the inserts for wear or for damage.
8. Inspect the springs for distortion.
9. Inspect the balls for wear or for flat spots.
10. Inspect the synchronizer sleeve teeth (1) for the following which may cause shift problems:
^ Grated teeth
^ Chipped off teeth
^ Blunted teeth
11. Inspect the synchronizer sleeve detent stops (2) for wear or being chipped off.
12. Replace the synchronizer assembly if the teeth or stops show the above conditions.
13. Inspect the synchronizer blocker rings for worn away grooves.
14. Replace the blocker ring assembly if the blocker ring grooves are worn away.
15. If dual cone, inspect the center ring for worn or damaged friction material.
16. Replace the synchronizer assembly if the center cone is worn or damaged.
17. Inspect the synchronizer blocker rings for worn shift teeth.
18. Inspect the center ring for being warped or damaged.
19. Inspect the inner ring for worn grooves.
20. Replace the synchronizer ring assembly for any of the above conditions.
21. Measure the blocker ring to gear clearance.
21.1. Assemble the correct blocker ring to the correct gear.
21.2. If dual cone, install both cones. Ensure the top edge of the friction cone is parallel to the gear.
21.3. Apply pressure to the blocker ring to fully seat the ring.
21.4. Using a feeler gauge measure between the blocker ring teeth and the teeth on the gear.
^ The measured valves for the 1st gear to synchronizer clearance is 1.070 - 1.870 mm (0.042 - 0.074 inch).
^ The measured valves for the 2nd gear to synchronizer clearance is 1.07 - 2.12 mm (0.074 - 0.083 inch).
^ The measured valves for the 3rd gear to synchronizer clearance is 0.925 - 1.585 mm (0.036 - 0.062 inch).
^ The measured valves for the 4th gear to synchronizer clearance is 0.975 - 1.535 mm (0.038 - 0.060 inch).
^ The measured valves for the 5th gear to synchronizer clearance is 0.950 - 1.560 mm (0.037 - 0.061 inch).
^ The measured valves for the reverse gear to synchronizer clearance is 1.170 - 1.720 mm (0.0426 - 0.068 inch).
22. It using a NEW blocker ring and the standard clearance can not be obtained replace the gear.