DISASSEMBLY



NOTE: RING GAPS MUST BE MEASURED WITH SYNCHRONIZER RING BIASED TOWARDS GEAR CLUTCHING TEETH ON GEAR CONE AS MUCH AS POSSIBLE WHILE MEASURING GAPS.

Before disassembly of the input shaft (1), it is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings (2, 5, and 8) and the speed gears. The correct gaps are listed below:

  • 3rd - 0.73-1.53 mm (0.029-0.060 in)
  • 4th - 0.77-1.57 mm (0.030-0.062 in).
  • 5th - 0.73-1.53 mm (0.029-0.060 in)
  • Reverse Brake - 0.505-1.74 mm (0.020-0.068 in.)

The reverse brake measurement is taken between the stop ring and case.

If a stop ring gap does not fall within the specifications, it must be inspected for wear and replaced. If the 1st or 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced.

The input shaft incorporates the 3rd, 4th, and 5th speed gears and synchronizers on the assembly.