Does anyone know where I can find a write up on how to replace the synchros? I have the tranny out now and might as well replace them since my 2nd gear and reverse is about gone. Thanks
#3631, "RE: Write up on replacing synchro's" In response to Reply # 0 Nov-06-04 01:48 PM by Star Turbo Talon
Best i can offer mike is to take it apart like a puzzle, have plenty of room to lay the parts out your first time so you know how it goes back together. I dont know of a writeup but emailing Dino will help if you get stuck. I have found an exploded diagram on the internet but its really not good and i cant find the link.
few things to remember....1/2nd gear you cant get parts to repair the synchros. the shaft can be disassembled if you have a press but its pretty much useless if you cant get parts.
anerobic sealer is needed for the cases..... be very careful with re-assembly of the cases, the output shaft bearing has a plastic cage and can be broken easily.
#3632, "RE: Write up on replacing synchro's" In response to Reply # 1
this process isnt hard, but you do need a press to press out the shafts out of the bearings. and be carful, the output shaft (1,2) is one peice so to speak, but the input shaft (3,4,5) is many little peices, and there isnt anything holding the peices on except the bearing you press the shaft off of. so watch out for falling parts when you press them out. and have an extra set of hands when trying to reinstall it into the case. you need to hold the assembly together (input shaft, output shaft, shift forks, and other misc shit). have fun.
#3634, "RE: Write up on replacing synchro's" In response to Reply # 3
Actually you dont need a press.....Dino guided me on that one already. Use a cheap socket and a hammer to tap the shafts out. Obviously you need to tap them out together not just one at a time. Once they are out you can sand them with emery cloth and oil so that futur assy and dis-assy is easier. Dont over due it, the shafts must be tight in the bearing races.
#3641, "RE: Write up on replacing synchro's" In response to Reply # 4
A press makes it SO much easier, though. I'd rather do it with a press than without.
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