Transaxale tools and rebuild

[Gary Whitaker]

Next is 1/2nd synchro hub but first it needs building back up and you need the tool as described in the manual to put the centre spring clip in

[Gary Whitaker]

Put the spring clip in the middle and gentle push the tapered end through the ring gradually expanding it in to the groove position the ends of the spring in one of the smaller quadrants

[Gary Whitaker]

Now place the centre on the table put the ring over the top and push through , you may need a small screwdriver just to push the ends of the clip in the groove .
don't worry if it springs out one of mine went straight in the other was a pig

[Gary Whitaker]

Iam going to take a break now back later ?

[John A. Ross]

Gary

Wow, that was a marathon, many thanks for taking that time. Brill

[Gary Whitaker]

Next you put back the 3 sliding keys unfortunately I forgot to take any pics but it's described well in the manual just make sure the bottom of the clips are not resting on the inside of the key I had to grind a little of mine if there are any marks on the OD of the clips stone smooth you can't get them new so you have to use what you've got

[Gary Whitaker]

They should now push through with a click as the middle ring drops into the outer groove then push back with the same pressure .
Be careful with 1/2 sliding sleeve as it only has one outer groove and if you're not careful it will push straight through and the clip will spring out ? everybodys must have done it at sometime don't forget to oil as you go, not to much

[Gary Whitaker]

Slide on the shaft make sure the outer groove on the sliding sleeve faces away from the pinion head as per drawing in the manual at the same time fit the selector shaft

[Gary Whitaker]

The selector shaft lugs should measure.250" the groove in the synchro hub should measure .270" so check for wear

[Gary Whitaker]

When you fit the bulk rings make sure the 3slots locates over the 3 keys

[Gary Whitaker]

Next fit 2nd gear bush and gear plus a little oil the one with two pin holes in

[Gary Whitaker]

Fit the 2 pins and 2nd selective washer

[Gary Whitaker]

Next 3rd gear bush the one with 2small slots and 3/16 slot at the other end line the slots up before you put the gear on

[Gary Whitaker]

Put the gear on plus a little oil,fit the Woodruff key.

[Gary Whitaker]

Now fit the 3/4th synchro hub with the selector fork make sure you locate the 3slots on the bulk ring over the keys