## Manual Transmission

#### Synchro Ring and Gear Inspection

13-27

1. The synchroniser hubs and sliding sleeves are selected assemblies and should be kept together as originally assembled.

1. Clean synchroniser components with clean solvent and air dry.

1. Inspect the components for the following:

- Teeth for wear, scuffs, nicks, burrs or breaks.
- Inserts and insert springs for wear, cracks or distortion. Replace if these conditions are present.
- If scuffed, nicked or burred conditions cannot be corrected with a soft stone or crocus cloth, replace the components.
- Measure the clearance between block ring (A) and inserts (B). Replace components if not within the specified limit.

1st/2nd:

3.9 mm (0.154 in.) or less

3rd/4th, 5th:

3.7 mm (0.146 in.) or less

1. Measure the clearance between block ring (A) and gear (B). Replace components if not within the specified limit.

   NOTE: Replace gear assembly if evidence of engine braking can be seen on the dog teeth.

Standard:

1.5 mm (0.059 in.)

Limit:

0.8 mm (0.031 in.)

1. Measure the clearance between block rings (A) and synchronising cones (B) for 1st and 2nd gears by positioning 1st gear, then 1st and 2nd synchroniser assembly, then 2nd gear as shown. Replace the 1st and 2nd gear synchroniser assembly if the measurement exceeds the specified limit.

   NOTE: When reassembling synchroniser assemblies, each insert spring should support all three inserts and each opening portion of the insert spring should face the opposite direction from the other.

Standard:

1.5 mm (0.059 in.)

Limit:

0.8 mm (0.031 in.)

1. Clearance between clutch hub (A) and inserts (B).

Limit:

0.25 mm (0.0098 in.)

a a a