2. Check for damage to the bushing at its inner, front and rear ends.
3. Check up wear of end surfaces of a nave.
Replace the sleeve and synchronizer hub as a set.
Crackers and synchronizer spring
1. Check whether the central lug of the synchronizer key is worn.
2. Check if the spring is loose, deformed or damaged.
Transfers
1. Check the bevel gear and clutch wheel teeth for damage and wear.
2. Check if the surface of the synchronizer cone is rough or damaged or worn.
3. Check the gear bore and front and rear ends for damage and wear.
Assembly
1. Install the hub and the synchronizer sleeve so that they are located according to the figure shown.
2. The synchronizer sleeve has teeth interrupted in six places.
Assemble this sleeve with the hub so that the central tooth located between the two teeth, where there is a gap, touches the synchronizer key.
3. Install the synchronizer spring so that its protrusion can fit into the groove in the synchronizer crackers.
When installing the synchronizer springs, make sure that the front and rear springs do not face the same direction.
4. Install the needle bearing and third speed gear train on the input shaft.
5. Install the 3rd-4th speed synchronizer assembly onto the input shaft using the special tool (09432-33300).
Warning:
- 1. When installing the synchronizer assembly, make sure that the three synchronizer cotters are properly installed in the corresponding grooves of the synchronizer ring.
- 2. After installing the synchronizer assembly, check that the third gear gear rotates smoothly.
6. Install the needle bearing using the same special tool (09432-33300).
7. Install the synchronizer ring, needle bearing, fourth speed gear and spacer ring.
8. Install the circlip.
9. Install the rear bearing using the special tool (09432-33300).
10. Install the clamping ring.
11. Install the rear bearing bush using the special tool (09432-33300).
12. Install the front bearing using the special tool (09432-33300).