need help with Synchro PLEASE!!!!

awdtalon21 · 05-13-2008, 07:52 PM

im in the process of trying to replace my synchros and i dont know how to get the bearing sleeve off, or the 3rd gear.

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twicks69 · 05-14-2008, 06:16 AM

I edited your picture with the instructions needed.

Use at least a 7-ton press; I would reccomend a 20-ton press to do this gently and easily.

Follow the instructions written in the picture. If you have any more, just add them to this thread, and I will help you through it.

Large text box reads:
"Place your gear puller in between the 3/4 hub and 3rd gear synchro with the curved side of your gear separator facing the 3rd gear synchro, and the flat side facing towards the 3/4 hub. Pull gently, you may trash the synchro or damage the 3/4 hub. Be extremely slow in pressing this part off and be sure to use a Red ScotchBrite pad or 600-grit sandpaper on the shaft after the parts are removed to clean the surface. Then be sure to use some clean paper towels and a can of Brake Clean prior to re-lubricating the shaft and pressing on your new parts."

Small text box reads:
"Be sure to clean the shaft surface after taking off the 4th gear bearing spacer and relubricating before pressing this part back on. It sucks to take it off sometimes."

I have had good luck and bad luck removing this part sometimes. Sometimes you trash the 3rd synchro and the 3/4 hub/slider, and sometimes it presses off quite nicely. It will be a smoother process when you use a larger hydraulic press.

awdtalon21 · 05-14-2008, 08:44 AM

I dont think the gear puller will fit between the 3/4 hub and 3rd gear synchro. Do you know what size puller i need?

twicks69 · 05-14-2008, 09:20 AM

Quote:

Originally Posted by awdtalon21

I dont think the gear puller will fit between the 3/4 hub and 3rd gear synchro. Do you know what size puller i need?

I usually use OTC 1124 = 1/2" - 5 3/4" span

eBay Motors: OTC 1124 Bearing Splitter 1/2in 5 to 3/4in Bearing Tool (item 300216556527 end time May-15-08 08:33:10 PDT)

OTC 1124 - Bearing Splitter 1/2 - 5-3/4 Capacity

Amazon.com: OTC 1124 1/2" to 5-3/4" Bearing Splitter: Automotive

This tool is extremely helpful in removing every part from your transmission.

If the 5th intermediate gear is ever an issue in removal, I reccomend using:

OTC 1123 (medium bearing separator):
Large OTC Bearing OTC Bearing Splitter OTC-1123 - eBay (item 250246165273 end time May-15-08 13:52:48 PDT)

with:

OTC 927 10-ton push/puller:
OTC 927 10 Ton Push-Puller - ToolKing.com

or

OTC 1122 (small bearing separator):
OTC 1122 1/8" - 2" Capacity Bearing Splitter - ToolKing.com

or

OTC 4518 push/puller set with small and medium bearing separators:
OTC 4518 Stinger 5 Ton Bar Puller/Bearing Separator Set - ToolKing.com

Good luck,

awdtalon21 · 05-14-2008, 09:40 AM

thanks very much, very helpfull.

awdtalon21 · 05-21-2008, 03:34 PM

dude i bought the tool you told me to get and i still cant get it off.

Rob10_99 · 05-21-2008, 03:38 PM

Will it not fit in between the synchro and sleeve?

awdtalon21 · 05-21-2008, 03:43 PM

it fit but it broke the hub

twicks69 · 05-21-2008, 04:13 PM

Well, I did state that sometimes it works, and sometimes it destroys the 3/4 Hub.

Replace it with a new 3/4 Hub and Slider with Synchros and springs and Keys:
1 x MD747647 (H.D. 3/4 Hub and slider with synchros and keys)
2 x MD742445 (H.D. 3/4 Hub and slider key springs)

Good luck,

awdtalon21 · 05-21-2008, 04:52 PM

well it broke the hub and i still cant get the bearing sleeve off.

awdtalon21 · 05-21-2008, 06:40 PM

here is what happend

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awdtalon21 · 05-21-2008, 06:41 PM

http://img442.imageshack.us/img442/9917/picturezb3.jpg

twicks69 · 05-22-2008, 05:32 AM

Well, you can do a few things, press it off using your bearing separators, getting under the broken hub; grinding a notch line around the 4th gear spacer and using the bearing separator on that, and pressing it off; trashing the Input shaft by cutting off the shaft and spacer to save the 3rd gear; or:

Bring it to a professional and let them remove it for you on a 20-ton press.

Sometimes they break, but I have only broken 1-2 like yours. I ended up getting them off, but it was definitely alot of time wasted.

awdtalon21 · 05-22-2008, 09:44 AM

i just want to make sure im doing it right. what is the 4th gear spacer, can you show me on the picture please.

twicks69 · 05-22-2008, 02:19 PM

Quote:

Originally Posted by awdtalon21

i just want to make sure im doing it right. what is the 4th gear spacer, can you show me on the picture please.

The picture I attached in post #2 -- it is the metal sleeve that is pressed onto the input shaft, with the right-hand-side arrow pointing to it.

JackM · 05-30-2008, 10:22 AM

You guys are doing it completely wrong. The gear below the hub is 3rd gear and it is a floating gear. Just press out the 3rd gear and the hub and needle bearing sleeve above it will come off too. You can use a puller, but it needs to be a big one.

Jack

twicks69 · 07-20-2008, 09:18 AM

Jack is right, and I was a complete idiot in this post -- I gave the wrong location for removal of the gearset. With a 20-ton press, this location is a snap to remove the 3/4 gearset.

The proper location for pulling the gearset is at:>

Cesar · 07-20-2008, 06:24 PM

lol, that sucks. I feel for you bro.

It'll be worth it. go a little tight on the preloads.