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.
Synchronizer Ring
- Check clearance "a" between synchronizer ring (1) and gear (2) while lightly pushing synchronizer ring by hand, and also check chamfered tooth of synchronizer outer ring. Replace with new one if necessary.
Clearance "a" between synchronizer ring and gear (4th, 5th, 6th and reverse)
Standard: 1.0 - 1.5 mm (0.040 - 0.055 in.)
Limit: 0.7 mm (0.020 in.)
- Put the synchronizer outer ring (1), inner ring (3) and the cone (2) together and then measure the step difference between the outer ring and the inner ring. And also check each chamfered tooth of synchronizer ring and replace with new one, if necessary.
Difference between synchronizer outer ring and inner ring (3rd)
Standard "b": 0.95 - 1.25 mm (0.038 - 0.049 in.)
Limit "b": 0.48 mm (0.019 in.)
- Check clearance "a" between synchronizer inner ring (2) and gear (1) as well as clearance "b" between synchronizer outer ring (4) and gear (1) respectively.
If measured value "a" or "b", whichever is smaller, is out of specifications replace new synchronizer inner ring (2), synchronizer center cone (3), synchronizer outer ring (4) and/or gear. And also check each chamfered tooth of synchronizer ring and replace with new one, if necessary.
Clearance "a" between synchronizer inner ring and gear, or clearance "b" between synchronizer outer ring and gear, whichever is smaller (1st and 2nd)
Standard: 0.75 - 1.65 mm (0.030 - 0.064 in.)
Limit: 0.38 mm (0.015 in.)
NO RELATED
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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.