Minimum Parts for a Proper Rebuild
3 Synchro Rings
1 Synchro Sleeve
1 Front Seal
1 Rear Seal

The following instructions assume that 4th and 5th gear synchros function properly. Inspect them before following these instructions. It also assumes that this procedure has not been done already. Check the ‘reverse’ side of the 5th gear synchro sleeve for wear before continuing.

Install the 3 new synchro rings on 1st, 2nd, and 3rd gears since these synchros suffer the worst wear.
Install the new sleeve between 1st and 2nd gears since the 2nd gear synchro and sleeve suffer the worst wear.
Remove the sleeve used for 5th gear and place it between 3rd and 4th. The ‘reverse’ side of the slider should be placed toward 3rd gear. Since reverse is not synchronized, there is no wear on the reverse side of the slider ring gear. This effectively gives you a new sleeve on 3rd gear. The 5th gear side of the sleeve gets minimal wear and will be quite adequate for 4th gear.
Remove the sleeve used for 3rd and 4th gears and place it between 5th and reverse.

Face what was the 4th gear side toward 5th gear. 4th gear gets minimal wear and will be quite adequate for 5th gear.
Install the front and rear transmission seals.
Fill the transmission with fluid before driving! See page 40 for Redline Gear Oil.

New synchronizers require a break-in period. Be aware of this and shift the car gently until things begin to move smoothly. NEVER shift the transmission hard or fast when the transmission is cold. Synchros are always stiff when cold regardless of whether they are new or well worn. Learn to double-clutch when down shifting into 2nd gear for extended transmission life. If you don’t wish to do a complete double-clutch, give the engine a little gas while the clutch pedal is depressed as you shift into a lower gear. This will match the engine/transmission speed with the rear axle/road speed for less wear on the transmission and for smoother downshifts. Ideally, when this is done properly, there should be no change in engine speed and no jerky motion when the clutch pedal is fully released. Happy Shifting!

- back to Tips and Techniques -