Synchronizers

Disassembly

NOTE: The following procedures apply to all synchronizer assemblies. The gear synchronizers are slightly different in design. Notation is made where procedural differences occur.

1. Before disassembling the synchronizer, scribe alignment marks on the sleeve and hub for assembly reference.

2. On fifth gear synchronizer only, remove the insert retainer.
   
   
   
   

3. Using a screwdriver, remove the two synchronizer retaining springs. Remove the inserts.
   
   
   
   

   NOTE: The first/second gear synchronizer is available only as an assembly with the output shaft. The synchronizer hub is pressed onto the output shaft with an interference fit; therefore, no attempt should be made to separate the hub from the shaft. The retaining springs, inserts, detent ball and spring are available for service. If the hub or sleeve is worn, the output shaft and synchronizer must be replaced as an assembly.

4. On the first/second gear synchronizer only, the synchronizer sleeve should be removed carefully to prevent loss of the detent ball and spring.
   
   
   
   

Assembly

NOTE: When assembling a synchronizer sleeve and hub, match the alignment marks made during disassembly. The sleeve and hub have an extremely close fit and must be held square during assembly to prevent jamming. Do not force the sleeve onto the hub.

1. Assemble the inserts and synchronizer retaining springs onto the sleeve and hub. The retaining springs engage the same insert but rotate in opposite directions.
   
   
   
   

2. On fifth gear synchronizer only, install the insert retainer. Ensure the retainer tabs are positioned over the synchronizer inserts.
   
   
   
   

3. On the first/second gear synchronizer only, install the detent ball and spring into the hub on the output shaft.

   Assemble retaining springs, inserts and sleeve onto hub. Refer to illustration in Step 1 for positioning of the retaining springs and inserts.