Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Inspection After Disassembly
INPUT SHAFT AND GEARS
Check items below. If necessary, replace them with new ones.
- Damage, peeling, dent, uneven wear, bending, etc. of shaft
- Excessive wear, damage, peeling, etc. of gears
SYNCHRONIZER
Check items below. If necessary, replace them with new ones.
- Damage and excessive wear of contact surfaces of coupling sleeve, synchronizer hub and shifting insert
- Coupling sleeve and synchronizer hub must move smoothly.
- If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.
BAULK RING CLEARANCE
- Single-cone synchronizer (4th, 5th, and 6th)
Push baulk ring on the cone and measure the clearance between baulk ring and cone. If measurement is below limit, replace it with a new one.
Clearance Standard value Refer to BAULK RING CLEARANCE . Limit Value Refer to BAULK RING CLEARANCE .
- Double-cone synchronizer (3rd)
Check the clearance between outer baulk ring, synchronizer cone, and inner baulk ring as follows.
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.