7A1-20
MANUAL TRANSMISSION
5) Apply puller (1) to 1st gear (2) and drive out low speed synchro-
nizer sleeve & hub assembly (3) with gear by using press.
6) Disassemble synchronizer sleeve & hub assembly (3).
7) Take out needle bearing from shaft.
8) Remove R bearing cone (1) by using puller (2), metal stick (3)
and press.
Inspection and Reassembly
1) Clean all components thoroughly, inspect them for any ab-
normality and replace with new ones as necessary.
2) If synchronizer parts (1) need to be repaired, check clearance
“a” between ring (1) and gear (2), each chamfered tooth of gear,
ring and sleeve, then determine parts replacement.
Clearance “a”: Standard 1.0 – 1.4 mm (0.039 – 0.055 in.)
Service limit 0.5 mm (0.019 in.)
3) To ensure lubrication, air blow oil holes (1) and make sure that
they are free from any obstruction.
4) Fit low speed synchronizer sleeve (1) to hub (2), insert 3 keys
(3) in it and then set springs (4) as illustrated left.
NOTE:
No specific direction is assigned to low speed synchro-
nizer hub (2) or each key (3) but it is assigned as assembly.
Size of low speed synchronizer keys and springs are the
largest compared with those of high speed and 5th speed
ones.
