I've been working on the 5th synchro replacement, and it was going smoothly- took everything apart per dgeesman's writeup and found a broken 5th synchro. I replaced it with a new one from malloy mazda and I just put on the 5th gear and the little silver ball&washer.

Now, when I try to slide the lower set of c-washers into the groove that is just above the silver ball's washer they will not go in - it's like the c-washers are too thick or the synchro+gear+silver-ball-washer is about a mm too high... any suggestions? Is it supposed to be a tight fit? should I try to force the c-washers in their groove or try to press down the 5th gear? I'm pretty sure I put the synchro on right and I took care to align the gaps with the gaps on the hub. When on the synchro would only rotate a few teeth distance in either direction. Also, it was difficult to get the little ball to go back in to its hole in the mainshaft.

Anybody else ever had this problem? have any suggestions?

 

hey little cat i was just wondering...im gonna have to do that my self here in a little bit...could you possibly add some pix to this so we can see what our talking about ...i like to kinda learn from other peoples experiences... also on a side note...what ship are you attached to?

 

there should be a pretty loose fit with the c washers, they slide right in and out.

 

is this the c-washers above or below the main bearing? if they are above, the bearing may not be fitted down far enough.

 

thanks for the replies - it was the c-washers below the main bearing and above the 5th gear.

I went back and managed to get the little ball out again(not easy after I had more or less jammed it in) and took off the 5th gear and synchro again. I put it back together again and this time everthing went together with no problems. I guess I just didn't have the synchro seated right....so, for those of you who are planning this in the future, the little ball and c-washers above it should fit in their respective hole/grooves easily and with no force.

I'd post pics but I don't know how to upload pics to this website...

regards
me

p.s. I was on a Destroyer(DDG) and an Amphib(LSD), but now I'm in flight school

 

To post pics, simply be sure the file is less than 100000 bytes (100kB) and use the "Manage Attachments" button below the part where you type in the message. If it's a reply, you have to go to the "Go Advanced" page to see this button.

Anyway, it sounds like you have things sorted out. When you place 5th synchro, note the 3 pockets in the ring and the keys in the 5/R hub. The pockets fit over the keys, and thus limit the synchro to rotating a maximum of one-half dog tooth in each direction. If the ball/ring don't fit, it's because the assembled parts underneath it aren't fitting right. The c-washers should slide right in with very little clearance, but not a physically tight fit.

Dave

 

damn littlecat...nice work man good luck with your school...u gonna fly 18s or helos? and thanx for the tip and info...i think i have about enought info to perform mine as well...as i am on cruise right now..sitting in lovey thailand right now as i type this...i cant relly do it but ive been ready to get my hands dirty and learn more about this money pit i call an obsession..i mean...car...

GET SOME BOYZZZ!!!

 

Checking in 24 years later to say Thank You! I was stuck here for a couple days with this issue till i triend to find this weird issue. You will swear that synchro fell in just right but gotta watch it slip in and line things up.
ill share a Pic hoping to explain the issue better for the next person who finds this gem when stuck.

So the bottom sad face is soo close you feel like maybe it needs some "persuasion" to fit but not the case this time. That probably means syncro did not seat properly even though it looks good (took me 3 tries to seat it before i found this). Top is how those "C" shaped clips should sit above and below the main bearing if you did it correctly.

 

Since this thread has been brought back from the dead, I figured I'd ask here. Is there anyway to tell the condition of the 5th gear synchro with out driving? Currently have a roller that will be getting a motor in the near future and was planning to just wait till the car was driving to see the condition of the trans. However if there is a good way to inspect the synchro with the trans still in the car and without it running, I'd rather find out and pull it now while car is down anyway than when it has a motor.

 

Im not positive and wish I could me more help but I think it would be very hard to tell.

Mine was only apparent when I shifted into 5th at higher RPM like 4k ish so got in the habit of shifting early into 5th like 3k. Got soo used to it, I almost forgot it was an issue 😅. One day I saw the parts I ordered years ago to ago, and knew I had to addres it.

If that car came with any aftermarket bracing where the Trans mounts is or even the diff mount on back, those help prevent this issue so a little better odds of it being okay. Maybe if it was babbied by the last owner too odds are better that it's okay but honestly it seems like lot to if you don't know if it's an issue. Job wasn't super hard but by no means easy for a DIY'r dude in his garage who watches too much YouTube.