1st and 2nd Gear Synchromesh Unit

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.





Disassembly

NOTE: When dismantling the transmission to components, place tool output shaft assembly tool No. 87 92 103, or equivalent, over the gear wheels to keep the synchromesh together.





1. Cut off the strapping band and remove tool 87 92 103 from the synchromesh unit.





2. Lift out the 2nd gear wheel and its bearing sleeve.
3. Lift out the synchromesh.
4. Remove the locking spring from the clips.
- Lift out the sleeve and place the clips in a safe place.
5. Lift out and turn the synchromesh hub.
- Remove the locking spring on the bottom side.
6. Lift out the 1st gear's synchromesh from the gear wheels.
7. Check the condition of all parts as regards wear.
- Replace damaged or defective parts.
- Measure the wear on the trisected synchromeshes by installing them into their respective places.
- Measure with a feeler gauge in three places between the large baulk ring and the carriage wheel and calculate a mean value.
- New synchromesh 1.4-1.5 mm
- If the mean value is less than 0.8 mm, the synchromesh should be changed.





Assembly

NOTE: Lubricate all parts with suitable 10W30 engine oil before they are installed.

1. Assemble and install the 1st gear's synchromesh on the 1st gear wheels.





2. Place the synchromesh hub in the sleeve; the sleeve should be placed with the fork groove facing downwards.

NOTE: The notches for the clips in the sleeve should face the clips' notches in the synchromesh hub.

3. Place and install the three clips.
- Install the locking spring clockwise.
- Turn carefully and then install the locking spring on the bottom side anti-clockwise.

NOTE: The locking springs on both upper and bottom side should hook into the same clip.





4. Place the sleeve (side with the fork groove downwards) and the synchromesh hub on the 1st gear's synchromesh.
- The notches in the synchromesh hub should install over the heels in the synchromesh.





5. Assemble and install the 2nd gear's synchromesh on the 2nd gear's gear wheels.
- Install the bearing sleeve in the 2nd gear's gear wheel and install the entire unit in the sleeve and the synchromesh hub.
- The heels on the baulk ring should install in the notches in the synchromesh hub.
6. Hold down the gear wheels and change gears as a test.





7. Install an output shaft assembly tool over the synchromesh unit so that it does not fall apart during assembly.