900 S Sedan V6-2498cc 2.5L DOHC (1995)
Input Shaft: Service and Repair
5th Gear's Synchromesh Unit
NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.
Disassembly
1. Lift out the sleeve.
2. Lift out the synchromesh hub and the baulk ring.
3. Lift out the needle bearing from the pinion.
4. Check the wear on the baulk ring by placing it on the 5th gear's pinion.
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Measure with a feeler gauge in three places and calculate a mean value.
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If the mean value is less than 0.5 mm, the synchromesh should be changed.
5. Check the condition of the parts regarding wear etc. and replace damaged or defective parts.
Assembly
Lightly oil all parts with suitable 10W30 engine oil.
1. Place the needle bearing in the 5th gear wheel.
2. Check that the wire coil on the baulk ring is installed and install the baulk ring on the 5th gear wheel.
3. Insert the synchromesh hub with the three notches over the heels of the baulk ring.
4. Install the sleeve with the flat side facing upwards.
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The high heels on the sleeve should fit into the deep teeth on the synchromesh hub.
5. Hold the synchromesh unit together and test changing gear by pressing down the sleeve over the synchromesh.
