Synchronizer - Gearbox - Set

Sychroniser - Gearbox - Set

Service Repair No - 37.20.07

Disassembly

1. Remove gearbox selector fork set.





2. Using tool LRT-99-002 and support bars under 1st gear, press output shaft bearing from output shaft.





3. Remove 1st gear, bearing collar, needle roller bearing and synchromesh rings.
4. Noting its fitted position, remove 1st/2nd gear synchronizer hub, 2nd gear synchromesh rings, 2nd gear and needle roller bearing.





5. Using tool LRT-99-002 and support bars under 3rd gear, press off output shaft pilot bearing.





6. Remove spacer, 3rd / 4th gear synchronizer hub, synchromesh baulk rings, 3rd gear and needle roller bearing.
7. Remove output shaft.

Reassembly

1. Clean output shaft, synchronizer hubs, gears and bearings.
2. Position output shaft in protected vice jaws, output end upwards.
3. Fit 2nd gear bearing, 2nd gear and synchromesh baulk rings onto output shaft.
4. Position 1st / 2nd synchronizer hub onto output shaft. Ensure that baulk rings are correctly located in hub.
5. Position 1st gear synchromesh baulk rings, needle roller bearing, 1st gear and bearing collar onto output shaft. Ensure baulk rings are correctly located in hub.
6. Remove output shaft from vice.





7. Using tool LRT-37-001, LRT-37-044 and LRT-99-002, press taper bearing onto output shaft.





8. Check end float of 1st gear using a feeler gauge between gear and collar flange:
^ New = 0.05 - 0.20 mm (0.002 - 0.008 in)
^ Service limit = 0.327 mm (0.012 in)





9. Check end float of 2nd gear using a feeler gauge between gear and output shaft flange:
^ New = 0.04 - 0.21 mm (0.0016 - 0.0083 in)
^ Service limit= 0.337 mm (0.013 in)
10. Invert output shaft in vice and fit 3rd gear, bearing, baulk rings, 3rd / 4th synchronizer and spacer.
11. Remove output shaft from vice.





12. Using tool LRT-99-002 and a suitable mandrel press pilot bearing onto output shaft.





13. Check end float of 3rd gear between gear and flange on output shaft.
^ New = 0.11 - 0.21 mm (0.004 - 0.0083 in)
^ Service limit= 0.337 mm (0.013 in)
14. Fit gearbox selector fork set.