M/T - Synchronizer Ring Installation Procedure

GROUP: TRANSAXLE

NUMBER: 95-40-007

DATE: JUNE, 1995

MODEL: ALL w/MANUAL TRANSAXLE

SUBJECT:
SYNCHRONIZER RING INSTALLATION PROCEDURE

DESCRIPTION:

This bulletin provides the procedures to follow when repairing "gear clash" conditions. Even if new parts are being used during the repair process, the following procedures must be followed to provide the best fit between synchronizer components and to reduce the possibility of gear clash from occurring.

SERVICE INFORMATION:

1. Confirm gear clash condition exists, and which gears are affected.

2. If gear clash exists, remove and disassemble the transaxle. Locate and remove gear/cone and synchronizer of affected gear range(s).




3. Place synchronizer ring onto gear/cone and rotate with light pressure to seat the ring onto the cone. Measure gap between top of gear and bottom of synchronizer ring. If gap is less than 0.5 mm (0.019 in.), replace synchronizer ring (Fig.1).

4. Place either the original or a new synchronizer ring onto gear/cone and rotate with light pressure to seat the ring onto the cone. With your fingers on the synchronizer ring, try to rock the ring on the cone. Move the position of your fingers 120° around the ring and try to rock the ring again. Repeat after moving your fingers another 120°. If the synchronizer ring can rock on the cone, proceed to step 5. If the synchronizer ring fits properly, steps 5 through 9 are not required.

5. Clamp gear/cone into vise with cone side up (use a soft jaw vise, or, if using a standard vise, protect gear with two blocks of wood, heavy cloth, etc.).




6. Apply fine lapping compound to cone surface (Fig. 2).




7. Place synchronizer ring on the gear/cone. To make lapping easier, put synchronizer hub and sleeve assembly on the synchronizer ring (Fig. 3)




8. Using a light back and forth twisting motion, lap synchronizer ring to gear/cone (Fig. 4). After 10 back and forth cycles, check synchronizer ring to gear/cone fit and gap, (step 3, Fig. 1). Lapping process is complete when synchronizer ring and gear/cone contact is uniform. Check for uniformity by using the procedure outlined in step 4. If necessary, repeat lapping in 10 cycle operations and recheck synchronizer ring to gear/cone fit until uniformity is achieved.

9. After lapping process is completed, remove all traces of lapping compound from synchronizer ring and gear/cone. Any lapping compound remaining on the components will wear away the synchronizer assembly and result in damage to the transaxle.




WARRANTY INFORMATION: