Clutch and 3-4 Syncro Install *Pics - Dodge SRT Forum
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post #1 of 33 (permalink) Old 08-19-2007, 10:07 PM Thread Starter
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Clutch and 3-4 Syncro Install *Pics

Some pics from the weekend




Massive amount of clutch dust that was coming out of the old clutch:


DCR Powershift:


This 3rd and 4th gear. The bigass nut on the left side has to come off. Unfortunately I don't have the tools to do it, so I might have to take it to the dealer

One side of the syncro actually moves around a little in there, more then it should. This is why getting into third gear was crunchy.

1-2, 5-R:

- John
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post #2 of 33 (permalink) Old 08-20-2007, 01:39 PM Thread Starter
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Got that bigass nut off of the 3rd gear shaft without taking to a dealer, and got the new syncro in. Gears are back together, nut torqued and staked. Trans is going back together soon.

- John
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post #3 of 33 (permalink) Old 08-20-2007, 01:49 PM
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I'm a huge fan of tranny disassembly photos. I can't wait until the day comes when I get to dig back into mine.
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post #4 of 33 (permalink) Old 08-20-2007, 01:52 PM
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how difficult is it to pull those pieces out and inspect?
I have my tranny out right now for TOB/fork replacement. Curious to know the effort involved to check they sync's out?

Quote:
Originally Posted by Dole Smelly
Just for the record, the torque setting for the oil drain plug is 20 ft-lbs, not infinity.
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post #5 of 33 (permalink) Old 08-20-2007, 02:16 PM Thread Starter
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Quote:
Originally Posted by rasp
I'm a huge fan of tranny disassembly photos. I can't wait until the day comes when I get to dig back into mine.
Luckily my gears all look good. I'll take some more pics for ya. hah

Quote:
Originally Posted by cali
how difficult is it to pull those pieces out and inspect?
I have my tranny out right now for TOB/fork replacement. Curious to know the effort involved to check they sync's out?
I got a hold of the shop manual (PDF) so that made it a little easier. It's not too bad to take things apart.
  • The snap rings in the two bearings are a PITA, they have to come out before the top gear case can come off.
  • The shift assembly has to come out and there's a bolt behind one of the selectors. (whatever it's called).
  • Rod that the 1-2, 5-R forks slide on comes right out.
  • There's an external bolt that holds reverse gear that comes out.
  • You don't have to pull any bearings to get all the gears out. Everything should just slide out.

More then likely if your syncros are bad you would've already had problems getting into a gear or two, but the outer rings on the syncro will be loose. There is a clutch like material on the inside of these rings the wears away. If you let this go too long you can damage the gears.

To get the syncros out the entire input shaft assembly has to come apart, which is the prob I ran into. The bearings/some gears are pressed on and have to be pulled. The 3-4 assembly has that big nut that has to be removed (and re torqued/staked when put back together - recommend new nut from mopar)

The forks just come out, there is nothing holding them in besides the shaft they're on, and the grove int he syncro.

- John

Last edited by tavenger5; 08-20-2007 at 02:19 PM.
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post #6 of 33 (permalink) Old 08-21-2007, 06:53 PM
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Thanks for the info..I was referring to just pulling out the whole assembly just to look at it.
One other question, when pulling the shift selector plate off I can see down in the middle area and I can see a gear and 2 rings with teeth...what are those 2?

Quote:
Originally Posted by Dole Smelly
Just for the record, the torque setting for the oil drain plug is 20 ft-lbs, not infinity.
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post #7 of 33 (permalink) Old 08-21-2007, 07:10 PM
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Where did you get the synchro's? Last couple times I checked, they were unavailable.

OG owner of an 03 SRT4. Yes I'm old. I'm still faster than you.
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post #8 of 33 (permalink) Old 08-21-2007, 07:23 PM
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You cant just get the Blocker rings. You have to get the synchronizer assembly.

So if your 3rd gear went out. You would need the 3/4 synchro assembly. It will come with the hub, sleeve, and both blocker rings. Last time i checked it was about $300...

2005 - Flame Red SRT-4
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post #9 of 33 (permalink) Old 08-21-2007, 09:45 PM Thread Starter
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Quote:
Originally Posted by cali
Thanks for the info..I was referring to just pulling out the whole assembly just to look at it.
One other question, when pulling the shift selector plate off I can see down in the middle area and I can see a gear and 2 rings with teeth...what are those 2?
Er, the 3-4 syncro probably?

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Originally Posted by SkullingAxe
You cant just get the Blocker rings. You have to get the synchronizer assembly.

So if your 3rd gear went out. You would need the 3/4 synchro assembly. It will come with the hub, sleeve, and both blocker rings. Last time i checked it was about $300...
Yeppers. It's a dealer part. I think I got mine for $250 only cause I have a friend that could get parts at cost.

- John
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post #10 of 33 (permalink) Old 08-22-2007, 10:03 AM
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hey FSM indicates the parts in the syncro are servicable individually...but you cant but them in pieces?

Quote:
Originally Posted by Dole Smelly
Just for the record, the torque setting for the oil drain plug is 20 ft-lbs, not infinity.
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post #11 of 33 (permalink) Old 08-22-2007, 10:08 AM
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Quote:
Originally Posted by cali
hey FSM indicates the parts in the syncro are servicable individually...but you cant buy them in pieces?

Not the last couple times I checked. Also, the needle bearings are suspect for the third gear grind as well.

Where you able do get the trans out without pulling the K member?

OG owner of an 03 SRT4. Yes I'm old. I'm still faster than you.
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post #12 of 33 (permalink) Old 08-22-2007, 10:53 AM Thread Starter
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Quote:
Originally Posted by el_jefe
Quote:
Originally Posted by cali
hey FSM indicates the parts in the syncro are servicable individually...but you cant buy them in pieces?

Not the last couple times I checked. Also, the needle bearings are suspect for the third gear grind as well.

Where you able do get the trans out without pulling the K member?
yep, That's not in the way at all.

- John
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post #13 of 33 (permalink) Old 08-22-2007, 10:54 AM
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Does the syncro slide on the needle bearing?

I got the tranny out by removing:
1. Axles - only undid the strut knuckle bolts and pulled axles out that way.
2. TBody and adapter
3. Starter
4. Hot pipe
This assumes you dont have the stock intake....

Tranny jack helps! I never pulled a tranny out in my life, and I had this one out in about 2.5hrs by my self, as well as working with one hand (broken finger). I followed the how-to with pics and FSM.

I found a worn tob fork, and I'm contemplating checking out everything since I am here now.

Quote:
Originally Posted by Dole Smelly
Just for the record, the torque setting for the oil drain plug is 20 ft-lbs, not infinity.
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post #14 of 33 (permalink) Old 08-22-2007, 11:03 AM
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Quote:
Originally Posted by cali

Tranny jack helps! I never pulled a tranny out in my life, and I had this one out in about 2.5hrs by my self, as well as working with one hand (broken finger). I followed the how-to with pics and FSM.
Troof. I used to pull the trans and transfer case on my Jeep CJ-5 using the bench press method FTL

OG owner of an 03 SRT4. Yes I'm old. I'm still faster than you.
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post #15 of 33 (permalink) Old 08-22-2007, 12:11 PM
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I got more questions...
How you get the nut off? How'd you get the gears off? You got a press?
And what did you mean by one side of the syncro moves more than it should?

Quote:
Originally Posted by Dole Smelly
Just for the record, the torque setting for the oil drain plug is 20 ft-lbs, not infinity.
someone is watching me
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