Synchronizer R&R

5TH GEAR AND 5TH REVERSE SYNCHRONIZER Removal and Inspection

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

1. Position car on hoist.

2. Place transaxle in any gear except 5th or reverse.

3. Raise car.

4. Remove driver's side wheel.

5. Drain transaxle fluid.

6. Remove left inner splash shield.





7. Remove rear cover bolts and rear cover, and discard gasket.





8. Remove 5th/Reverse fork retainer(s) and push the fork forward to engage 5th gear with the synchronizer sleeve to lock transaxle into two gears.

9. Remove the input shaft nut.

10. Remove the reverse cone, thrust washer and blocking ring.

11. Remove the 5th/Reverse synchronizer and fork as an assembly. Inspect the notches in the lock notches in the synchronizer sleeve. If notches are square-cut as shown in Figure A at the beginning of the bulletin, the synchronizer can be re-installed. If the lock notches are not square, replace the synchronizer assembly.

NOTICE: Synchronizer hubs and sleeves must be kept together as matched sets. Hubs and sleeves are etched to show proper alignment.





5TH GEAR AND 5TH REVERSE SYNCHRONIZER INSTALLATION

1. Install the 5th gear synchronizer blocker ring to 5th gear.

2. Install the 5th gear synchronizer spring to 5th synchronizer.

3. Slide the 5th/Reverse fork over the 5th/Reverse synchronizer sleeve and install the sleeve to the hub and fork to the shift fork shaft at the same time.

IMPORTANT: Always use new retainers.

4. Install the synchronizer spring to the reverse blocker and install the assembly to the 5th/Reverse sleeve.

5. Install the reverse cone and thrust washer.

6. Move 5th/Reverse fork and synchronizer sleeve to engage 5th gear to lock transaxle into two gears at the same time.

7. Install shaft nut and torque.

IMPORTANT: Make sure that the threads on the shaft are clean and free of oil. A wire brush may be used to clean the threads of the shaft.

Torque: 150 N-m (110 lbs.ft.)

8. Unlock the shafts by moving 5th fork to the neutral gate.

9. Install the 5th/Reverse fork retaining rings using P/N 21120014. Two retainers are required.

10. Turn the reverse cone so one of the slots is facing the top of the transaxle (align cone to rear cover).





11. Install rear cover gasket.

NOTICE: Clean and lubricate fasteners with ATF (DEXRON(R)-II or equivalent) wipe. off excess fluid and install.

12. Install rear cover and install bolts and torque using a crisscross pattern.

Torque: 14 N-m (124 lbs.in.)





13. Install inner splash shield.

NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel lug nuts to loosen in service.

14. Position wheel onto hub.

15. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to be sure torque is correct.

Torque: 140 N-m (103 lbs.ft.)

16. Fill transaxle with fluid.