Synchronizer For 1ST Gear Has Been Modified, From Transmission Build Date 02 05 0

Synchronizer for 1st gear has been modified, from transmission build date 02 05 0, 02J, 5 Spd. M/T
The following components have been added or modified:
- A- Inner ring
- B- Outer ring
- C- Synchro-ring with additional recesses -4- for the lugs -1- of inner ring -A-.
- 1st gear wheel with additional recesses -3- for the lugs -2- of outer ring -B-.

Note: For the 2nd gear the same inner ring, outer ring and synchro ring are installed.

- If the components should not be replaced, ensure they are reallocated to the original gear.





Installation position of inner ring, outer ring and synchro-ring 1st gear:
- Place inner ring -A- on 1st gear wheel.
- Angled lugs (arrow 1) point toward outer ring -B-.
- Install outer ring -B-.
- Lugs (arrow 2) engage in gear wheel recesses (arrow 3).
- Install synchro-ring -C-.
- The recesses (arrow 4) engage in lugs (arrow 1) of inner ring -A-.





Check inner ring 1st gear for wear
- Press inner ring onto gear wheel cone and measure gap "a" with a feeler gauge.








Check synchro-ring 1st gear and outer ring for wear
- Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler gauge.








Assembling locking collar and locking pieces with 1st and 2nd gear synchro-hub
1 - Spring
2 - Locking collar
3 - Synchro-hub
4 - Locking piece
- With introduction of the modified 1st gear synchronizer the shoulder has the same width on both sides of synchro-hub.

The shoulder has a chamfer on one side (arrow B).
- After assembly the shoulder of the synchro-hub and the outer splines of the locking collar (arrow A) face same direction.
- Recesses for locking pieces on synchro-hub and locking collar (arrow C) must align one over another.





Installation position of locking collar/synchro-hub 1st and 2nd gear
- The locking collar splines (arrow) point to splines for 3rd/4th gear synchro-hub -A-.
- Remove the 1st gear synchro-hub as described and install again.