Modified 1ST Gear Synchronization From Transmission Build Date 02 05 0

Modified 1st gear synchronization 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 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 are not 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.

Angled lugs (arrow -1-) point towards outer ring -B-.

- Install outer ring -B-.

Lugs (arrow -2-) engage in gear 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 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 synchronization 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.





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 1st gear synchro-hub as described and install again.