M/T - Changes, Modifications
Group: 35Number: 92-01
Date: December 31, 1992
Subject:
5-speed transmission 02A, changes/modifications
Models:
Corrado, all m.y.
(see component descriptions below, for specific transmission build dates)
5th gear synchronizer, changes
Transmissions from 31 10 1
Note
The modified assembly has three new locking keys (item 4) which are additional to the three existing keys cast on the synchronizer ring.
1 - Springs for 5th gear synchronizer ring
^ no longer a single-spring design
^ installed position: one spring at 120~ offset to the other
2 - Synchronizer for 5th gear
^ three cutouts (arrows A) for new locking keys (item 4)
3 - Synchronizer hub for 5th gear
^ three smaller additional cutouts a for new locking keys (item 4)
^ dimension a = 8.2 mm
4 - Locking keys
^ installed position: smaller end (arrows B) toward edge of meshing teeth in synchronizer (item 2)
5th gear synchronizer ring, change
previous (transmissions up to 30 10 1)
^ dimension a = 9.0 mm
^ spring recess (lower arrow) is present
new (transmissions from 31 10 1)
^ dimension a = 8.6 mm
^ spring recess (lower arrow) has been eliminated
CAUTION
Do not install early version synchronizer rings in later transmissions, nor later version synchronizer rings in earlier transmissions.
Modified synchronizer ring and 5th gear synchronizer, assembling
Transmissions from 31 10 1
^ slide synchronizer over synchronizer hub (see also, illustration 35-1319)
^ edges A of meshing teeth in synchronizer face in same direction as collar B of synchronizer hub
^ cutouts for locking keys in synchronizer and in synchronizer hub must align, one above the other
^ insert locking keys, as shown in illustration 35-1319
^ insert springs at a 120~ offset, seating each spring under all three lugs C of the locking keys
^ be sure ends of spring (arrows) are positioned at lugs C, as shown
5th gear shift fork, changes
Note
Modifications to the 5th gear shift fork correspond to changes in the 5th gear synchronizer hub.
previous (transmissions up to 30 10 1)
^ dimension a - 35.0 mm
^ dimension b = 23.3 mm
new (transmissions from 31 10 1)
^ dimension a = 33.7 mm
^ dimension b = 24.3 mm
Note
The new shift fork can be installed in earlier transmissions.
1st/4th gear shift forks/ball bearings, changes
previous (transmissions up to 05 02 2)
^ dimension a = 20.0 mm
new (transmissions from 06 02 2)
^ dimension a = 21.0 mm
Note
The new shift fork with larger ball bearings can also be installed in earlier transmissions.
Modified 5th gear synchronizer, installed position
Transmissions from 31 10 1
^ assemble hub and synchronizer, as described previously
^ install so that teeth (arrow 1) in synchronizer, and high collar of synchronizer hub (arrow 2) face transmission housing
5th gear, adjusting/checking
Transmissions from 31 10 1
Adjusting
^ engage 5th gear
^ loosen bolt 1
^ press synchronizer and selector arm in direction of arrows
^ tighten bolt 1 to 25 N-m (18 ft.lb.)
Checking
^ check measurement with feeler gage
^ gap between synchronizer and gear must not exceed 0.2 mm
^ repeat adjustment if necessary
^ remove 5th gear:
^ synchronizer must now be in neutral position
^ synchronizer ring must have enough clearance to move freely
Selector shaft, changes
Depth of spring-loaded ball
Note
The spring-loaded ball is now imbedded deeper into the selector shaft. This modified design slows down the main shaft (via the selector shaft and 5th gear synchronizer), and eliminates the noise of shifting into reverse gear. previous (all transmissions up to 30 10 1)
previous (only transmissions NOT paired with VR6 engines, up to 03 12 1)
^ dimension a = 5.0 mm
new (only transmissions paired with VR6 engines from 31 10 1)
new (all transmissions from 04 12 1)
^ dimension a = 4.2 mm
Length/diameter changes
Note
Instead of a ball bearing for the selector shaft in the end cover, there is now a sleeve bearing. Accordingly, the lower end of the selector shaft is now shorter and has a larger diameter. previous (transmissions up to 30 10 1)
^ dimension b = 57.0 mm
^ dimension c = 15.0 mm
new (transmissions from 31 10 1)
^ dimension b = 41.0
^ dimension c = 16.0 mm
Introduction of detent element
Note
Beginning in April 1992, a selector shaft with a new detent element (arrow) was phased into production.
The new detent element can be installed in previous transmissions, with manufacture dates beginning 31 10 1.
End cover, changes
previous (transmissions up to 30 10 1)
^ dimension a = 21.0 mm
new (transmissions tom 31 10 1)
^ dimension a = 16.0 mm
Note
The end cover modifications correspond to changes in the selector shaft (i.e. shaft length and diameter changes).