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Synchronizer Centering: Synchronizers

  1. Install needle bearing inside input shaft. Assemble input shaft to mainshaft (without reverse driven gear and nut). Install mainshaft assembly in left side of transmission case. Install clutch housing. Install and tighten Allen screws in retainer plate (2nd version).
  2. For 1st version transmissions, install reverse pinion, Positioning Gauge (.0314-AG) and retaining nut. Push countershaft gear inward to eliminate bearing play. Pivot shaft in order to bring positioning gauge onto stud and maintain assembly with retaining nut. Place all shift forks in neutral position.
  3. Spread synchronizers apart between sleeve and hub to their maximum extent. Insert Gauge (.0314-AF) between each synchronizer sleeve and hub without forcing. If gauge fits easily between all 3 points, retain original shim. If gauge does not fit easily between all 3 points, determine which of the following conditions exists and perform adjustments to determine new shim size.
    Fig 1: Synchronizer Centering Adjustment (Except 4th Gear)
    G95J55698Courtesy of PEUGEOT MOTOR OF AMERICA, INC.
  4. If gauge does not easily fit between points 1 and 3, See Fig 1, View A. Insert gauge and feeler gauge at point 2. Insert feeler gauge of various thicknesses to determine amount of change. Reduce shim thickness by this amount.
  5. If gauge does not easily fit at point 1, See Fig 1, View B. Measure clearance at point 2 and note the reading. Reduce shim thickness by amount of reading obtained. 6) If gauge does not easily fit at point 3, See Fig 1, View C. Measure clearance at point 2 and note reading. Reduce shim thickness by reading obtained. If gauge does not easily fit at point 2, See Fig 1, View D. Measure clearance at points 1 and 3 and note reading.
  6. If clearance at point 1 is less than clearance at point 3, increase shim thickness by clearance reading obtained at point 1. If clearance at point 1 is more than clearance at point 3, increase shim thickness by reading obtained at point 3.
NOTE: This adjustment is made by changing size of shims located under input shaft bearing. Shims are available from .006-.020" (.15-.50 mm) in .002" (.05 mm) increments. Use as few shims as possible to reach desired thickness.
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