Input Shaft; Combination Of Gear And Synchronizer Ring; Chamfered Tooth Ends Of Ring - Suzuki Samurai 1986 Service Manual

Input Shaft

Referring to Fig. 13-34, inspect cone @ and
toothed ring @ for wear and damage.
Inspect gear teeth @I and splines @ for wear
and damage.
If any part of input shaft inspected as above
is found excessively worn or badly damaged,
replace shaft.
Fig. 13-34

Combination of Gear and Synchronizer Ring

Fit ring to cone of each gear, and measure
clearance between the two at peripheral teeth,
as shown in Fig. 13-35. If clearance exceeds
service limit, replacement is necessary.
Clearance between gear and ring
Standard
(0.039 - 0.055 in.)
5th speed
(0.047 - 0.063 in.)
Fig. 13-35
Inspect external cone (of gear) and internal
cone (of ring) for abnormal wear. Be sure that
contact patterns on these surfaces indicate
uniform full-face contact, and that surfaces are
free from any wavy wear. A badly worn member
must be replaced.
Proper synchronizing action on gear shifting can
be expected only when ring-to-gear clearance
(Fig. 13-35) and condition of cone surfaces,
among other things, are satisfactory.
Fig. 13-36 @I Checking con tacting surface
Chamfered Tooth Ends of Ring (External
Teeth) and Sleeve (Internal Teeth)
Synchronizer ring and hub have three slots each,
in which keysare carried as backed by expanding
springs, so that the hub and its two rings, one
I
on each end, are capable of running together.
Since the sleeve is engaged by its internal teeth
with the hub as if the two were splined together,
the sleeve, too, runs with the hub and rings.
mm
0.5
(0.019 in.)
I
In meshing action, the sleeve is pushed (by the
shifter fork) to one side, so that if slides axially
on the hub, pushing the ring toward the cone
surface of the gear. This push is transmitted by
three keys, which are lightly gripped by the
sleeve.
13-13