Disassembling and Assembling Complete Synchronization

Disassembling and Assembling Complete Synchronization

- Output Shaft Removed -

Disassemble output shaft

Note: Only use the molybdenum coated synchromesh rings for repairs. Check distance between synchromesh ring and clutch. Measure in area of stops.

Note: The synchromesh ring must be pressed on by screwing for measurements. Synchromesh rings must bear uniformly on the entire surface.





Disassemble synchronization.
Thrust piece (1), spring (2) and ball (3).

Installation:

Bore (4) in operating sleeve must be aligned with ball (3).





Install all springs, thrust pieces and balls.

Note: Shouldered end of thrust pieces faces sliding sleeve.
Place guide sleeve halfways in sliding sleeve.
Push in balls far enough until guide sleeve can be pressed into sliding sleeve.





Modified Synchronization Since 5.85:
Sliding sleeves with asymmetric splines.
Thrust pieces (1), spring (2) and balls (3) in weaker version.

Installation:

Bevelled ends of thrust pieces face the sliding sleeve.
For the 3rd/4th gear guide sleeve it is important
to make sure that the bevelled end of sliding
sleeve (marked with 3 grooves) face the long collar (4) of the guide sleeve.