THIS IS NOT MY WRITE UP. I simply saved this for other people so DON'T contact me about the tools.
You will need the following parts/supplies as a minimum:
5th gear Synchro.
sealant (Permetex, Yamabond etc.)
section of the shop manual as reference.
Here is what the two updated parts look like:
You also may need the following special tools:
size External and internal snap ring pliers
Bearing Pullers* or SST
ft.-lb Torque wrench
*I will loan out my custom pullers needed. You will have to
send me $20, the cost of the tools plus shipping and I will mail them out to
you. Preferably Payal. After you are done, mail them
back and when I receive them, I will refund the cost of the tools minus the
shipping. Please borrow the tools when you are ready to use them and do not
keep them for more than a week.
I think the shift select spindle makes a big difference. Highly recommended. Synchro and shift select spindle should
be less than $100. Also, the updated synchro is a different color. New one is a
bronze color while the old is more brass looking.
it upright on the bell housing.
sure it is in neutral and remove the shifter.
shift select spindle can be installed on the extension housing at any
time. They are held on by 2-10mm head bolts.
the 14mm head bolts on the extension housing. Some will be tight due to
the sealant on the threads.
the extension housing and lift upwards. You may need to tap on it with a
a punch, remove the roll pins out of the shift. Note the orientation.
the speedometer gear. There will be 2 snap rings on either side. Also
between the shaft and gear, is a “woodruff” key to prevent the gear from
rotating independently from the shaft.
a mallet tap the bearing housing upwards and remove it.
transmission should look similar without the bearing housing. Note: The
rear main bearing rear C-washers, circlips and counter 5th gear
bolt have been removed in this picture.
the snap ring, washer, and retaining ring holding the two C-washers
together. Also Remove the two C-washers and mark them as the rear.
the rear main bearing using the long puller. Try to keep the puller
parallel with the shaft when tightening.
the retaining washer holding the two c-washers. Also remove the two
C-washers and mark them as the front.
a punch again, uncrimp the tab on bolt holding the 5th
countergear. The bolt will rotate, so you will may
need to keep it from rotating. I used an air impact wrench, which did not
require me to hold the shaft. Remove the bolt.
the small puller, remove the counter bearing.
the counter 5th gear.
a mallet tap the center housing upwards and remove it.
the reverse idler gear and washer.
front C-washers and retaining ring. Do not confuse them with the other C-washers.
the thrust lock washer and steel ball. Do not loose the steel ball!
5th gear and roller bearing.
broken 5th gear synchro is now visible and can be removed.
may want to replace the 5th gear clutch hub if it looks worn
like mine. The 5th gear clutch hub engages with the 5th
and install 5th gear Synchro.
- Use a
light coating of gasket sealant between the surfaces. Also make sure
counter 5th gear is torque to the appropriate range.
Hopefully this removes some
vagueness from the shop manual and you idea of the repair process. Good luck!