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

3. Replace synchronizer parts that are worn or damaged.

Replace a burred or nicked part that cannot be reconditioned by hand. Use a soft stone or a crocus cloth.

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 1.27-2.032 mm (0.050-0.080 in) for the 1st and 2nd gear.

The nominal gap is 0.79-1.57 mm (0.031-0.062 in) for the 3rd, 4th, 5th and 6th gear.