Disassembling and Assembling Complete Synchronization

Disassembling and Assembling Complete Synchronization






Disassemble output shaft
Check distance between synchromesh ring and clutch body.
Measure in area of stop.






Note: Twist and press down synchromesh formly for measuring. Synchromesh rings should bear uniformly on the entire surface.

Disassembling synchronization:
Press operating sleeve off of guide sleeve.
Spring (1), thrust piece (2) and ball (3).

Installation:

Flat teeth of operating sleeve must align with the thrust pieces.






Install all springs, thrust pieces and balls.

Note: Shouldered end of thrust pieces faces the collar. Press ball into the operating sleeve one after the other.






1st/2nd Gear Synchronization:
Check installed position of operating sleeve.
Wide surface end (4) of operating sleeve faces thicker collar (5).






5th/Reverse Gear Synchronization:
Check installed position of operating sleeve.
Wide surface end (6) of operating sleeve faces
narrow collar (7).