Synchronizer

SYNCHRONIZER / REMOVAL
To remove the 1/2 synchronizer assembly, the intermediate shaft must be disassembled. (Refer to MANUAL TRANSMISSION/DISASSEMBLY)
Disassembly

To remove the 3/4 or 5th gear synchronizer assembly, the input shaft must be disassembled. (Refer to MANUAL TRANSMISSION/INPUT SHAFT - DISASSEMBLY)
Input Shaft

To remove the reverse gear synchronizer assembly, the reverse shaft must be disassembled. (Refer to MANUAL TRANSMISSION/REVERSE SHAFT - DISASSEMBLY)
Reverse Shaft

Fig. 244 Synchronizer Disassembly:

DISASSEMBLY
1. Remove synchronizer sleeve (Fig. 244). Three (3) synchronizer strut assemblies will free from hub.
2. Inspect all components for wear and replace as necessary.

Fig. 245 Measuring Synchronizer Wear:

Input Shaft:

Output Shaft:

INSPECTION
Install blocker ring to gear as shown in (Fig. 245). Using feeler gauge, measure wear limit (between blocker ring and gear).




VISUAL INSPECTION
Inspect for scuffed, nicked, burred, broken teeth, or general wear

Inspect strut assemblies for wear, distortion, and functionality of ball and spring

Fig. 244 Synchronizer Disassembly:

ASSEMBLY
Install synchronizer sleeve to synchronizer hub (Fig. 244). Install three (3) strut assemblies.



INSTALLATION
To install 1/2 synchronizer assembly, (Refer to MANUAL TRANSMISSION/ASSEMBLY).
Assembly


To install 3/4 or 5th gear synchronizer assembly, (Refer to MANUAL TRANSMISSION/INPUT SHAFT - ASSEMBLY)
Input Shaft


To install reverse gear synchronizer assembly, (Refer to MANUAL TRANSMISSION/REVERSE SHAFT - ASSEMBLY).
Reverse Shaft