Synchronizer Ring: Service and Repair

REMOVAL
1. Remove rear cover. (Refer to "Rear Cover Removal.")
2. Place transaxle in 1st gear.
3. Remove 5th/Reverse fork retainer and discard.
4. Move 5th/Reverse fork to lock transaxle in 5th gear.
5. Remove input shaft nut and discard.
6. If required, remove output shaft nut and discard.
7. Remove reverse cone, thrust washer, and reverse blocker assembly.
8. Remove 5th/Reverse shift fork.





9. Remove 5th Reverse synchronizer, 5th/Reverse blocker assembly, and 5th drive gear.

IMPORTANT: Synchronizer hub and sleeve must be kept together as a match set. Note spline alignment marks on hub and sleeve (3rd/4th synchronizer shown, 5th/Reverse synchronizer similar). If alignment marks are not visible, put new marks on hub and sleeve before they are separated.





IMPORTANT: If the 5th/Reverse hub is press fit on the input shaft:
a. Install shaft protector, SA9211T-3 on the end of the input shaft with the counter bore in the shaft protector going over the input shaft.
b. Install the 5th driven gear remover, SA9211T-2 on the input shaft. Engage the legs of the puller under the clutching teeth ring on the 5th drive gear and center the forcing screw on the shaft protector.
c. Tighten the forcing screw to remove the 5th drive gear along with the 5th/Reverse hub.

10. Remove 5th driven gear, if required.

IMPORTANT: If the 5th driven gear is press fit on the input shaft:
a. Install shaft protector, SA9211T-3 on the end of the output shaft with the counter bore in the shaft protector going over the output shaft.
b. Install the 5th driven gear remover, SA9211T-2 on the output shaft. Engage the legs of the puller under the 5th driven gear and center the forcing screw on the shaft protector.

IMPORTANT: It may be necessary to release the bearing snap-ring and pull the shaft out to provide access for the puller under the 5th driven gear.

c. Tighten the forcing screw on the puller to remove the 5th driven gear.








INSTALLATION
1. Install 5th driven gear (if removed).

IMPORTANT: If the 5th driven gear is press fit on the input shaft:

a. Place the 5th driven gear on the output shaft engaging the splines.
b. Thread the 5th driven gear installer, SA9211T-1 onto the output shaft until it is snug. (5th/Reverse hub shown, 5th driven gear similar.)

IMPORTANT: Before installing the 5th driven gear installer SA9211T-1, make sure that the nut is backed off all the way on the forcing screw.

c. Tighten the nut on the forcing screw until the 5th driven gear has been seated.

2. Install the 5th gear thrust washer (if removed).
3. Install the 5th gear bearing race (if removed).
4. Install the 5th gear bearing.
5. Install the 5th gear.
6. Install the 5th gear synchronizer blocker ring to 5th gear.
7. Install the 5th gear synchronizer spring to 5th blocker ring.





8. Install the 5th/Reverse hub onto the input shaft.

IMPORTANT: Be sure tabs on blocker ring are aligned with slots on hub.(3rd/4th synchronizer shown, 5th/Reverse synchronizer similar.)

IMPORTANT: If the 5th/Reverse hub is press fit on the input shaft:
a. Place the 5th/Reverse hub on the input shaft engaging the splines.
b. Thread the 5th driven gear installer, SA9211T-1 onto the input shaft until it is snug.

IMPORTANT: Before installing the 5th driven gear installer SA9211T-1, make sure that the nut is backed off all the way on the forcing screw.

c. Tighten the nut on the forcing screw until the 5th/Reverse hub has been seated.

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





IMPORTANT: Be sure to align the mark on the sleeve to the mark on the hub as shown (3/4 synchronizer shown, 5th/Reverse synchronizer similar).

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





11. Install the reverse cone and thrust washer.
12. Lock the transaxle in two gears by shifting into 1st gear, and moving the 5th/Reverse shift fork into 5th gear at the same time.

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

13. Install a new input shaft nut and torque.
- Torque: 150 N.m (111 ft. lbs.).
14. If removed, install a new output shaft nut and torque.
- Torque: 150 N.m (111 ft. lbs.).
15. Unlock the transaxle by moving the 5th/Reverse shift fork into the neutral position.
16. Install the 5th/Reverse fork retainer.

IMPORTANT: Always use new retainers.

17. Install the rear cover and wheel. Refer to the "Rear Cover Installation" procedures.