2. Lift the 4th gear with the needle bearing. If the bearing needs to be removed from the gear, mark the bearing location in the gear with paint.
3. Remove the 4th gear synchronizer ring.
4. Remove the retaining ring securing the synchronizer hub and remove the hub from the shaft.
5. Remove the 3rd gear synchronizer ring, 3rd gear and needle bearing.
6. Mark the gear and bearing so that the bearing is not upside down during assembly.
7. Before assembly, check that all parts are clean.
8. Lubricate the 3rd gear needle bearing with transmission oil and install it on the shaft.
9. Install the 3rd gear.
10. If the synchronizer has been disassembled, assemble it so that the hub is installed according to the marks. Late models do not have marks, but are assembled with the hub groove and the wide part of the sleeve to the 4th gear.
11. Install three locking crackers into the hub before installing the bushing, then secure the crackers with the retaining rings. The location of the retaining rings is shown in Fig. 6.4, the sharp end of the spring is inserted into the locking cracker.
12. Install the 3rd gear synchronizer ring on the gear cone, measure the gap shown in Fig. 6.5. This gap should not exceed the value given in Specifications, otherwise install a new synchronizer ring.
13. Note that the grooves in the synchronizer hub bore have a groove at one end. Use this end to place the hub on the shaft. Place the 3rd gear. Its hub also has a groove at one end (Fig. 6.32), this side should face the 4th gear.
14. Fit the synchronizer onto the input shaft by first rotating the 3rd gear synchronizer ring so that the grooves on it are aligned with the synchronizer locking crackers.
15. Insert the snap ring onto the synchronizer hub, then press the synchronizer back away from the snap ring. This will increase the gap between the synchronizer and the 3rd gear, which provides better lubrication for the 3rd gear bearing.
16. Install the 4th gear synchronizer ring, aligning the grooves in it with the synchronizer locking crackers, check the gap as described in point 12.
17. Install the 4th gear and bearing, first lubricating them with transmission oil, install the thrust washer and finally the retaining ring.
18. Measure the axial clearance between the 4th gear and the thrust washer. This clearance should be 0.20 - 0.35 mm, a smaller clearance is better. The retaining rings are available in different thicknesses to obtain the required clearance, namely 1.65, 1.70 and 1.75 mm. Note that on later gearboxes the shaft was changed and the thrust washer is not installed. Instead, a single retaining ring of greater thickness is used, the axial clearance is no longer adjustable.
