Synchronizer Ring: Service and Repair

Disassembly





- Remove the circlip from the gear. Check all parts for wear and damage and replace as necessary.

Checking





- Using a micrometer, check diameter of installed synchronizing ring. Place micrometer at the highest point of the synchronizing ring.
^ Diameter: 3rd, 4th, and 5th speed = 76.3 ± 0.18 mm
1st and 2nd speed = 86.37 ± 0.17mm





- Maximum clearance between selector fork and shifting sleeve of 1st through 5th speed.
^ Dimension a = 0.5 mm (0.02 in.).

Assembly
- Insert stops and synchronizer ring.





1st gear synchronizing parts
A - Asymmetric double shift band
B - Synchronizer ring with groove





2nd gear synchronizing parts
C - Synchronizer ring without groove
D - Symmetrical double shift band





3rd, 4th and 5th gear synchronizing parts
E - Split shift band

NOTE: A coat of molybdenum is sprayed on the rough surface of a synchronizer ring. Different loads are applied to both sides of a synchronizer ring during a shift. Consequently when repairing, the synchronizer ring should always be turned so that the rough side faces the operating sleeve.

A-Circlip:

A - Circlip

- Install circlips.
Circlip for 3rd, 4th and 5th gears must be inserted so that stepped end faces the guide sleeve.