Procedures

Removing 5th Gear
- A = Separation device, 22-115 mm, e.g. Kukko 17/2






Removing Synchronizer Hub For 3rd And 4th Gear
- A = Separation device, 22-115 mm, e.g. Kukko 17-2

Note: Push the 3rd gear synchronizer ring (arrow) toward the 3rd gear before installing the separation device.






Installing Spring In Gear
- Place spring (arrow) into gear by hooking angled end into hole.






Checking Synchronizer Ring For Wear
- Press synchronizer ring into operating sleeve and measure gap -a- with feeler gauge in positions -A-, -B- and -C-.
- Add readings together and divide by 3 to obtain average.

The result must not be less than 0.5 mm (0.020 in).






Installation Position Of Operating Sleeve
- The chamfered side (arrow -1-) faces 4th gear.
- The smaller-diameter side (arrow -2-) faces 3rd gear.






Pressing On Synchronizer Hub For 3rd And 4th Gear






Determining Thickness Of Circlip For 4th Gear
- Determine the thickest circlip that can just be inserted in the groove, and install it.
- Select circlip for 5th gear in the same way.
- Available circlips: refer to "Location of Circlips" described below.






Location Of Circlips
- Thickness of circlips -1-, -2-, -4- and -5- must be determined. Circlip -3- is always the same thickness.
- Circlips -1- and -2-, determining thickness: refer to "Determining Thickness Of Circlip For 4th Gear" as described above.
- Circlip -3-, color. brown, Part No. N 902 945, 2 mm thick






- Circlip -4-, color: blue






- Circlip -5-






Pressing On 5th Gear
- The higher collar faces reverse gear.
- The oil retainers face 4th gear.