Disassembling and Assembling Complete Synchronization

Disassembling and Assembling Complete Synchronization

-Output Shaft removed-







Disassemble output shaft

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

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






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

Installation:

Bores (5) or flattened teeth on the operating
sleeve must be aligned with ball (3).






Note: Only for 3rd/4th Gear Synchronization:

Version with One Groove:
Groove of operating sleeve must be on end with the narrow collar.







Version with Two Grooves:
Grooves of operating sleeve must be on end with the wide collar (1).







Install all springs, thrust pieces and balls.

Note: Shouldered end of thrust pieces faces the operating sleeve.
Insert guide sleeve in operating sleeve to half its length.
Press in balls for enough until the guide sleeve can be pressed into
the operating sleeve.