Cleaning & Inspection
- Check all parts for wear or damage. Replace any damaged or worn parts. Ensure all mating parts engage and disengage smoothly. Check clearance between each shift fork and sleeve. If clearance exceeds .039" (1.00 mm), replace worn part. Check clearance between synchronizer ring and cone.
- Fit synchronizer ring to cone of each gear and measure clearance between bordering teeth. See SYNCHRONIZER CLEARANCE SPECIFICATIONS table. If clearance is not as specified, replace worn or damaged synchronizer. Check synchronizer ring key slot width. If width is not .398-.409" (10.11-10.39 mm), replace synchronizer ring.SYNCHRONIZER CLEARANCE SPECIFICATIONS
Application In. (mm) Low & High-Speed Standard .039-.055 (1.00-1.40) Service Limit (Minimum) .020 (.51) 5th Speed Standard .047-.063 (1.19-1.60) Service Limit (Minimum) .020 (.51) - Install synchronizer assembly on mainshaft. Push in and twist each synchronizer. If 1/3 mesh between ring and gear cone does not occur, replace entire synchronizer assembly. See Fig 2 .
- Check fork shaft locating springs. Free length should be .826-1.004" (21.00-25.50 mm). If not, replace springs. Check radial clearance between sliding yoke and bushing bore. If standard clearance is not .0010-.0035" (.025-.089 mm) or service limit of .0078" (.198 mm) is not met, replace bushing and sliding yoke together. DO NOT replace bushing only.