13. Synchronizers Assemble

Synchronizers Assemble

If you are servicing this transmission for a shifting concern such as clash, hop out of gear, or block-out in a particular gear, the following hardware must be replaced as a set for the gear in question. Adjoining gears do not need to be serviced unless necessary:

* Main gear in question - for example 2nd, 3rd

* Synchronizer Assembly

* Blocker Ring Assembly

* Shift Fork Inserts

5th/6th Gear Synchronizer





Note:
Ensure that the hub slides easily.

1. Apply lubricant and install the following components into the 5th/6th synchronizer hub (124/118):

* The 5th gear blocking ring (121b)

* The 6th gear blocking ring (121a)






2. Apply lubricant to the blocking ring, driven gear and sleeve. Install the following components into the reverse gear (206):

* The reverse gear insert (120) and the spring (195)

* The reverse gear blocking ring (122)

* The reverse driven gear (112)

* The synchronizer sleeve (125)

1st/2nd, 3rd/4th Gear Synchronizer





1. Install the synchronizer insert and spring into the synchronizer hub. Press the spring and slide the insert in.





Note:
When you service the synchronizers, retain them in the same order that they are removed. Keep the synchronizer components together and mark them to identify correct location.

2. Apply lubricant to the cones and blocking rings. Align and install the following components into the 1st/2nd gear synchronizer hub (115/117):

* The 1st gear synchronizer inner cone (96)

* The 1st gear synchronizer outer cone (97)

* The 1st gear outer blocking ring (98)

* The 2nd gear outer blocking ring (98)

* The 2nd gear synchronizer outer cone (97)

* The 2nd gear synchronizer inner cone (96)





3. Apply lubricant to the blocking rings. Install the following components into the 3rd/4th gear synchronizer hub (116/118):

* The 3rd gear blocking ring (104)

* The 4th gear blocking ring (121)