Note: Synchronizer cage and hub must be replaced as an assembly.
1. Using a chuck to hold the bearing inner race, press the race onto the output shaft.
2. Measure the clearance between the 2nd and 3rd gears.
- Standard: 0.06-0.21mm
- Limit: 0.3mm
3. If the clearance is greater than the specified limit, measure the thickness of the 3rd gear.
- Standard; 34.92-34.97mm
- Limit: 34.8mm
If the thickness of the 3rd gear is less than the specified limit, replace the 3rd gear with a new one.
If the thickness of the 3rd gear is within specification, replace with a new 3rd/4th synchronizer hub.
4. Measure clearance between 4th gear and spacer (top figure in center column).
- Standard: 0.06-0.21mm
- Limit: 0.3mm
5. If the gap is greater than the specified limit, measure the distance (A) on the spacer.
- Standard: 26.03-26.08mm
- Limit: 26.01mm
6. If distance (A) less than the specified limit, replace the spacer with a new one.
If the distance (A) within limits, measure the thickness of the 4th gear.
- Standard: 31.42-31.47mm
- Limit: 31.3mm
If the thickness of the 4th gear is less than the specified limit, replace the 4th gear with a new one.
If the thickness of the 4th gear is within specification, replace with a new 3rd/4th synchronizer hub.
7. Measure the clearance between the spacer and the 5th gear.
- Standard: 0.06-0.21mm
- Limit: 0.3mm
8. If the clearance is greater than the specified limit, measure the distance (IN) on the spacer.
- Standard: 26.03-26.08mm
- Limit: 26.01mm
9. If distance (IN) less than the specified limit, replace the spacer with a new one.
If the distance (IN) within limits, measure the thickness of the 5th gear.
- Standard: 30.92-30.97mm
- Limit: 30.8mm
If the thickness of the 5th gear is less than the specified limit, replace the 5th gear with a new one.
If the thickness of the 5th gear is within specification, replace with a new 5th synchronizer hub.