Step 2

STEP 2

Synchronizer key

Standard Dimension:

NOTE: There are two (2) types of synchronizer key.






NOTE: The styles and sizes of synchronizer rings are different as shown in the illustration.

Synchronizer ring and clutch hub assembly






NOTE: Align the synchronizer ring groove and clutch hub key when installing.

Primary Shaft Gear




1. Install the needle bearing and the 3rd gear.

NOTE: Apply transaxle oil to the needle bearing.

2. Install the synchronizer ring and clutch hub assembly with the SST.




3. Install the synchronizer ring.
4. Install the ball and gear sleeve.
5. Install the needle bearing and the 4th gear.

NOTE: Apply transaxle oil to the needle bearing.

6. Install the new bearing inner race with the SST.




7. Install the new bearing inner race with the SST.




8. Measure the clearance between the 3rd gear and primary shaft gear.
If clearance is not within specification, replace any part which is worn or damaged.

Clearance: 0.150-0.262 mm (0.0059-0.0103 in)




9. Measure the clearance between the 4th gear and bearing inner race. If clearance is not within specification replace any part which is worn or damaged.

Clearance: 0.150-0.262 mm (0.0059-0.0103 in)

Secondary Shaft Gear




1. Install the thrust washer.
2. Install the needle bearing and the 1st gear.

NOTE: Apply transaxle oil to the needle bearing.

3. Install the synchronizer ring and clutch hub assembly (reverse gear).




4. Install the synchronizer ring.
5. Install the ball, gear sleeve and needle bearing.

NOTE: Apply transaxle oil to the needle bearing.




6. Install the 3rd gear, the secondary 3rd gear, spacer and the secondary 4th gear.
7. Install the new bearing inner race with the SST.

NOTE: Check that the spacer does not rotate.




8. Install the new bearing inner race with the SST.




9. Measure the clearance between the 1st gear and thrust washer.

Clearance: 0.130-0.354 mm (0.0051-0.0139 in)




10. Measure the clearance between the 2nd gear and secondary 3rd gear.
If clearance is not within specification, replace any part which is worn or damaged.

Clearance: 0.150-0.262 mm (0.0059-0.0103 in)