Measuring Low Gear Shim Thickness, Synchro

- Adjustment range = a - b
- Dimension b = x - y





- Measure dimension a
^ Example: a = 77.8 mm

- Measure dimension x
^ Example: x = 77.6 mm





- Measure dimension y
^ Example: y = 1.0 mm

Compute Shim Thickness
- Dimension b = x - y
^ Example: 77.6 mm minus 1.0 mm = 76.6 mm (b)

- Adjustment range = a - b
^ Example: 77.8 mm minus 76.6 mm = 1.2 mm





- Select proper shim from table and install shim, low gear disc, and needle bearing in low gear housing
- Position new gasket





- Install bearing retainer with grease (arrow)
- Rotate transmission 180 (1/2 turn)
- Push low gear housing from below, guiding gear and shim to drive pinion
- Install mounting bolt and tighten to 20 Nm (15 ft lb)
- Install reverse idler gear cover
- Push splined sleeve onto drive pinion
- Install output housing, tighten bolts to 20 Nm (15 ft lb)
- Install back up light switch and shift shaft lever after removing transmission from repair stand