Gear Components: Inspection: Synchronizers

WARNING: This page is about a different car, the 2003 Nissan Pathfinder. However, it is still accessible from the selected car via links, so may be relevant.

Check spline portion of coupling sleeves, hubs, and gears for wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
Check insert springs for deformation.

Fig 1: Checking Spline Portion Of Coupling Sleeves
Courtesy of NISSAN MOTOR CO., U.S.A.
Measure wear of main drive, 1st and OD baulk rings.
Clearance between baulk ring and gear:

Refer to SERVICE DATA AND SPECIFICATION (SDS) .
If the clearance is smaller than the wear limit, replace baulk ring.

Fig 2: Measuring Clearance Between Baulk Ring & Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Measure wear of 2nd and 3rd baulk rings.
1. Place baulk rings in position on synchronizer cone.
2. While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "B".
  Standard:
  
  A 0.7 - 0.9 mm (0.028 - 0.035 in)
  
  B 0.6 - 1.1 mm (0.024 - 0.043 in)
  
  Wear limit:
  
  0.2 mm (0.008 in)
  
  Fig 3: Measuring Wear Of 2nd Baulk Ring
  Courtesy of NISSAN MOTOR CO., U.S.A.
If dimension "A" or "B" is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.

Fig 4: Measuring Wear Of 3rd Baulk Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Measure wear of reverse baulk ring.
1. Place baulk ring in position on reverse cone.
2. While holding baulk ring against reverse cone as far as it will go, measure dimension "A" with dial indicator.
  Dimension "A":
  
  Standard -0.45 to 1.05 mm (-0.0177 to 0.0413 in)
  
  Wear limit 0.7 mm (0.028 in)
3. If dimension "A" is larger than the wear limit, replace baulk ring.
  
  Fig 5: Measuring Wear Of Reverse Baulk Ring
  Courtesy of NISSAN MOTOR CO., U.S.A.