Page 21-17

DISASSEMBLY

1. Support the second speed gear on a press base, and press the rear end of the mainshaft to remove the bearing inner race, gear bearing sleeve, first speed gear, 1 - 2 synchronizer and second speed gear. (134020)

2. Remove the snap ring from the front end of mainshaft.

3. Remove the 3-4 synchronizer, third speed gear and needle bearing.



INSPECTION Synchronizer Ring

1. Check the synchronizer ring for worn and damaged internal threads.

2. With synchronizer ring assembled to the cone of each gear, check the dimension "A". If "A" is less than 0.5 mm (0.020 in.), replace the synchronizer ring and/or gear. (110009)

Synchronizer Assemblies

1. Inspect the synchronizer assemblies for wear or breakage. Make sure the sleeve moves freely on the hub.

2. Inspect the synchronizer springs for distortion.

3. Inspect the synchronizer keys for damage.
Gears and Shafts

1. Check all the gears for excessive wear, chips or cracks; replace as required.

2. Check shafts for bending, wear and worn splines; replace if necessary.

Bearings

1. Thoroughly clean the bearings and dry with compressed air.

Caution

Do not allow bearings to spin, as this will damage the races, balls and rollers. Turn them slowly by hand.

2. Exert lateral and radial pressure against the races and turn the bearings; check for rough or uneven feel.

3. Visually inspect all bearings for wear or damage.

Case and Housings

1. Inspect the transmission case and the extension housing for cracks or damage.

2. Inspect the front bearing retainer for cracks, distortion or damage.
Continues 1983 Starion Service Manual Page 21-18 21-17