For 1990-2009 cars

1. Clean all the synchronizer parts in a suitable solvent. Air dry all the synchronizer parts.
2. Inspect the synchronizer parts for the following conditions:

• | Burrs

• | Cracks

• | Chamfer for excessive wear

• | Free movement of the clutching sleeves on their hubs

• | Worn or damaged clutch teeth

• | Distorted springs

Important: Replace a burred or nicked part that cannot be reconditioned by hand.

3. Replace synchronizer parts that are worn or damaged.
4. Measure the gap between the vertical faces of the blocking ring teeth and the speed gear as follows:

4.1. | Assemble the correct blocking ring with the correct speed gear.

4.2. | The blocking ring must be fully seated on the gear.

4.3. | Use a feeler gauge to measure the forward gear gap.

4.4. | Use a feeler gauge to measure the reverse gear gap.

Measure the gap without the wave washer in between the blocking ring and the reverse gear.

The nominal gap is 1.27-2.16 mm (0.050-0.085 in) for the 1st and 2nd gear.

The nominal gap is 1.27-2.03 mm (0.050-0.080 in) for the 3rd, 4th, 5th and 6th gear.

Replace the friction cones and blocker rings when the gap is significantly less than specified.