Cushman TURF-TRUCKSTER, Service & Repair Manual

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the sleeve advances and slides into the ring, the ring
will be rotating nearly with the speed of the gear, so
that the sleeve can smoothly slide over into the clutch
teeth of the gear.
The initial contactor mesh between sleeve and ring is
determined by the widths of key and slot. The key
clearance in the slot should extend at least a third
(1/3) of the chamfer (see Figure 4G-16).
With the synchronizer properly assembled on the
shaft, push in and twist each synchronizer to see if
the one-third mesh occurs or not; if not, it means that
the overall wear (which is the sum of the wears of
slots, keys and chamfered tooth ends) is excessive
and, in such a case, the entire synchronizer assembly
must be replaced.
Inspect each synchronizer ring for wear of its key
slots by measuring the width of each slot. If the width
reading exceeds the limit shown in Figure 4G-17,
replace the ring.
FORK SHAFT LOCATING SPRINGS
Locating springs are used as retainers for the three
shifter fork shafts. If gears have been slipping out
of mesh, check these springs for strength by measuring
their free lengths (see Figure 4G-18), and replace
them if their free lengths are less than 0.727 inch
(18.45 mm).
GEAR SHIFT FORK SHAFTS
Check the shift fork shafts at the gear shift lever end
(see Figure 4G-10) for uneven wear. Replace worn
shift fork shafts.
EXTENSION CASE BUSHING
Check the bushing press-fitted into the extension
case for wear by measuring the radial clearance
between bushing bore and sliding yoke as shown in
Figure 4G-19. If the sliding yoke is capable of rattling
in the bush because of advanced wear it will cause
the drive shaft to rattle. For this reason, an extension
case found to allow the drive shaft yoke to rattle in
excess of 0.004 inch (0.1 mm) must be replaced;
replacement of the bushing alone will not fix the
problem.
DRIVE TRAIN
SECTION 4G. TRANSMISSION
(3-CYLINDER 660 GASOLINE ENGINE)
4G-10
Figure 4G-16. Checking Key Clearance
Figure 4G-18. Checking Locating
Spring Free Length
Figure 4G-19. Bushing-to-Yoke Clearance
Figure 4G-17. Synchronizer Ring Slot Wear
Standard Service Limit
Spring
0.807 inch 0.727 inch
Free Length
(20.5 mm) (18.45 mm)