Synchronizer Assembly - 5th/Reverse

Synchronizer Assembly - 5th/Reverse

Service Repair No - 37.20.38

Disassembly

1. Remove gearbox rear extension.
2. Remove 5th gear set.





3. Remove split needle roller bearing from output shaft.
4. Remove and discard Allen screw and remove gear change yoke.
5. Remove and discard circlip securing 5th/ reverse synchronizer hub to output shaft.
6. Remove synchronizer hub and selector fork assembly.

Reassembly

1. Clean gears, shafts, bearings and selector fork.
2. Position selector fork to synchronizer, fit assembly to output shaft and selector shaft. Fit new hub retaining circlip. The fit of the circlip is controlled by the selective washer behind the reverse gear bearing collar on the output shaft.
3. Adjust to give a reverse gear end-float of 0.005 - 0.055mm (0.0002 - 0.0021 in).
4. Apply Loctite 290 to threads of new gear change lever yoke Allen screw.
5. Position gear change lever yoke and tighten Allen screw to 25 Nm (18 ft. lbs.).
6. Position split needle roller bearing to output shaft.
7. Fit 5th gear set.
8. Fit gearbox rear extension.