Page 58
10
G
Synchronizer Gear Assembly, Continued:
6. Install the thrust washer (41) and two bearings (43) as shown (Figure 10-43, Page 53).
7. Install the input gear assembly (52), with the smooth collar toward the synchronizer ring as shown (Fig-
ure 10-43). The input gear should seat in the synchronizer ring.
8. Install the thrust washer (53) and then the spring (Belleville) washer (39). The spring washer should be
oriented with the raised center toward the end of the shaft (Figure 10-43, Page 53).
9. Press a new bearing (54) onto the shaft until it seats (Figure 10-43). Make sure the input gear turns
freely.
10. On the other end of the input shaft, install the thrust washer (41), and the synchronizer ring (45). The
smooth collar of the synchronizer ring should be oriented toward the clutch hub, and the notches in it
should mate with the synchronizer inserts as shown (Figure 10-43, Page 53).
11. Install the narrow bearing (44), wide bearing (45), and input gear (42) onto the shaft. The smooth collar
of the input gear should be oriented toward the synchronizer ring as shown (Figure 10-43). The gear
should seat inside the ring.
• APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY. APPLYING PRES-
SURE ANYWHERE ELSE WILL DAMAGE THE BEARING.
FIGURE 10-59
FIGURE 10-60
FIGURE 10-61
CAUTION
SYNCHRONIZER
INSERTS OVERLAP
SNAP RINGS
TOP VIEW
NOTCHED
SURFACES
OF SYNCHRO.
INSERTS FACE
OUT
SNAP RINGS TOP AND BOTTOM
SIDE VIEW
GROOVE ON END
OF CLUTCH HUB
LONG END
OF SHAFT
SYNCHRONIZER
SLEEVE
SYNCHRONIZER
CLUTCH HUB
WITH GROOVED END OF SYNCHRONIZER
CLUTCH HUB POINTING DOWN TOWARD
LONG END OF SHAFT, INSTALL IT
ONTO THE SYNCHRONIZER SLEEVE
SLIDE SYNCHRONIZER
RING ONTO CLUTCH HUB
WITH THE SMOOTH
COLLAR OF RING
TOWARD CLUTCH HUB
SYNCHRONIZER
RING
SYNCHRONIZER
CLUTCH HUB
Summary of Contents for 1997 DS
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