6. Synchronizers Cleaning and Inspection
Synchronizers Cleaning and Inspection1. Clean all the synchronizer parts in a suitable solvent. Air dry all the synchronizer parts.
2. Inspect the synchronizer parts for the following conditions:
^ Burrs
^ Cracks
^ Chamfer for excessive wear
^ Free movement of the clutching sleeves on their hubs
^ Worn or damaged clutch teeth
^ Distorted springs
3. Replace synchronizer parts that are worn or damaged.
Replace a burred or nicked part that cannot be reconditioned by hand. Use a soft stone or a crocus cloth.
4. Measure the gap between the vertical faces of the blocking ring teeth and the speed gear as follows:
4.1. Assemble the correct blocking ring with the correct speed gear.
4.2. The blocking ring must be fully seated on the gear.
4.3. Use a feeler gauge to measure the forward gear gap.
4.4. Use a feeler gauge to measure the reverse gear gap.
Measure the gap without the wave washer in between the blocking ring and the reverse gear.
The nominal gap is 1.27 - 2.16 mm (0.050 - 0.085 inch) for the 1st and 2nd gear.
The nominal gap is 1.27 - 2.03 mm (0.050 - 0.080 inch) for the 3rd, 4th, 5th and 6th gear.
Replace the friction cones and blocker rings when the gap is significantly less than specified.