1. Remove the synchronizer from the secondary shaft (see «Secondary shaft repair»).
2. Before disassembly, mark the position of the clutch 3 relative to the hub 1. Carefully disassemble the synchronizer by removing the clutch from the hub. At the same time, make sure that the spring-loaded crackers 2 with balls do not scatter in different directions.
3. Inspect the synchronizer parts. Chips and nicks on the splines of the hub and coupling are unacceptable (especially pay attention to the ends of the teeth of the coupling). Damage or seizing marks on crackers, balls and springs are also unacceptable. Replace defective parts or synchronizer assembly.
4. Install the coupling on the hub in accordance with the marks previously applied.
5. In this case, three large grooves on the splines of the coupling must coincide with the grooves of the hub for the clamps (with holes).
6. Lubricate the retainer spring with Litol-24 grease and insert it into the hole in the hub groove.
7. Lubricate the cracker with Litol-24 grease and insert a ball into its hole.
8. Compressing the spring, insert the cracker with the ball into the groove of the hub. Grooves a on the cracker must be directed outward, spherical (big) surface b must face the coupling.
9. Push the cracker so that the ball falls into the grooves on the splines of the coupling.
10. Adjust the spring with a screwdriver so that it gets into the cracker hole. Install the rest of the fasteners in the same way.