Assembling, From Transmission Build Date 25 May 2010
Checking the Inner Contact Surface for Wear on the 1st, 2nd and 3rd Gear Outer Rings
-- Install the inner race -1- on the cone on the gear.
-- Install the outer race -2- on the cone on the inner race. Measure the gap -a- with a feeler gauge at 3 locations at 120°.
-- Note the average value.
| Wear limit dimension -a- | |
|---|---|
| 1st, 2nd, and 3rd gear | 0.4 mm |
Checking the Outer Contact Surface for Wear on the 1st, 2nd and 3rd Gear Outer Ring
-- Check the synchronizer ring -arrow- on the inner running surface for grooves and radial wear, and replace if necessary.
-- Install the inner race, the outer race and the synchronizer ring on the cone on the inner race.
-- Press the synchronizer ring onto the outer races while turning it at the same time so that it seats correctly.
-- Measure the gap -a- with a feeler gauge at 3 locations at 120°.
-- Note the average value.
| Wear limit dimension -a- | |
|---|---|
| 1st, 2nd, and 3rd gear | 0.8 mm |
-- Install the 2nd gear wheel with the needle bearing.
Installed Position of Outer Race, Inner Race and Synchronizer Ring, 2nd Gear
-- Install the inner race -A- in the gear.
The tabs -1- face away from the gear.
-- Install the outer race -B-.
The tabs -2- engage in grooves -3- on the gear.
-- Install the synchronizer ring -C-.
The larger openings -4- lock in the tabs -1- on the inner race -A-.
Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears
- Spring
- Locking piece
- Locking collar
- Synchronizer hub
-- Slide the locking collar over the synchronizer hub.
In 3rd and 4th gear, the wide collar on the synchronizer hub and the locking collar face in one direction.
The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.
Assembly: Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears
The locking collar is pushed over the synchronizer hub.
-- Install the locking pieces and springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.
Installed Position: Locking Collar/Synchronizer hub for 1st and 2nd Gears
The identification groove -arrow 1- and the narrow collar -arrow 2- on the synchronizer hub face 1st gear.
Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears
The pins -A- on the synchronizer ring lock into the recesses -B- in the synchronizer hub.
-- Install the locking ring.
Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race
-- Install the synchronizer ring -A- in the synchronizer hub.
The tabs -1- lock in the openings -2- in the synchronizer hub.
-- Install the outer race -B- in the synchronizer ring.
The tabs -3- face away from the synchronizer ring.
-- Install the inner race -C- in the outer race.
The tabs -4- lock in the larger openings -5- in the synchronizer ring -A-.
Install 1st Gear with Needle Roller Bearing
- The synchronizer ring -1- and the tabs -arrow A- are inside the openings in the synchronizer hub -2-.
The pins -arrows B- in the outer race lock in the recesses -arrows C- in the gear -3-.
-- Install the thrust washers for 1st and 4th gears.
-- Install the 4th gear with needle bearing.
Checking the 4th Gear Synchronizer Ring for Wear
| -A- = brass synchronizer ring | ||
|---|---|---|
| Gap dimension -a- | Installed dimension | Wear limit |
| 4th gear | 1.0 to 1.7 mm | 0.5 mm |
| -B- = steel synchronizer ring | ||
|---|---|---|
| Gap dimension -a- | Installed dimension | Wear limit |
| 4th gear | 1.3 to 2.4 mm | 0.8 mm |
-- Press the synchronizer ring onto the taper of the gear and measure the gap dimension -a- using a feeler gauge.
Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears
The wider collar on the synchronizer hub -arrow- faces 3rd gear.
-- Place the synchronizer ring for 4th gear on the 4th gear selector gear.
Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears
-- Turn the synchronizer ring so that the grooves line up with the locking pieces.
-- Install the locking ring.
Installing the Outer Ring Synchronizer Ring and 3rd Gear Inner Ring
-- Install the synchronizer ring -A- in the synchronizer hub.
The tabs -1- lock in the openings -2- in the synchronizer hub.
-- Install the outer race -B- in the synchronizer ring.
The tabs -3- face away from the synchronizer ring.
-- Install the inner race -C- in the outer race.
The tabs -4- lock in the larger openings -5- in the synchronizer ring -A-.
Install the 3rd Gear Selector Gear with Needle Bearing
- The synchronizer ring -1- and the tabs -arrow A- are inside the openings in the synchronizer hub -2-.
The pins -arrows B- in the outer race lock in the recesses -arrows C- in the gear -3-.
-- Install the 3rd gear with the needle bearing.