REPAIR INSTRUCTIONS

4.Install the sliding clutch (with preload springs) over the synchronizer clutch housing and pins. Make sure the marked letter “R” on the clutch is facing in the same direction as the R marked on the pins.

5.Install the three support tubes into the synchronizer assembly.

With this sliding clutch design, it is very important to make sure that the clutch is facing in the correct direction when installed. This is due to the differing number of clutch teeth on the Lo-range and Hi-range sides of the range clutch. The Lo-range side contains 21 clutching teeth and the Hi-range side contains 22 clutching teeth. Incorrectly installing the sliding clutch prevents proper shifting.

6.Install the remaining synchronizer housing over the pins, tubes and springs. Align the housing with the pin heads.

7.Install the three 12-point screws, plus threaded and nonthreaded inserts into the largest holes of the synchronizer assembly.

Effective November 28, 2007, a revised fastener was implemented into production at this synchronizer location. These fasteners are one-time use only and must be replaced anytime the synchronizer assembly is disassembled.