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PostPosted: Mon Nov 04, 2013 11:01 pm 
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Cant do the smog without being able to downshift into second so here it is , had to open it up and look for myself if I can fix it somehow . Already have the synchro and all the pullers so we'll see. Last time I did something like this was at least ten years ago. Wish me luck. :|


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PostPosted: Tue Nov 05, 2013 12:23 am 
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You won't have a problem. Id strongly recommend doing first at the same time. You will very clearly see the issue with the synchro once you get it out and in your hand. The slots will be elongated. At the very least, see how the same slots(notches?) look on first synchro. It's only a snap ring away so not hard to physically check it.
It's a pain to have to go into these boxes, but once you take on the task, it really isn't bad at all. I've done a ton of them. At least it's a wear item that can still be found easily. The mk1 trannies are often harder to deal with because of part availability issues.

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PostPosted: Mon Nov 11, 2013 10:02 pm 
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Cody , thanks for the encouragement . When I took it apart it all came back to me. I had factory service manual to guide me and provide specifics. I did change both synchros , you were right , the slots were beat to hell . No wonder I could not down shift into second without rev matching. Interestingly , book tells you that first and second have a different size slots but the new one was not either size. I put them in anyway and thing is working like its brand new . Tomorrow Im off to smog check and when that is done next transmission is already apart waiting for new synchros ..............


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PostPosted: Mon Nov 11, 2013 11:23 pm 
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DTM GTi wrote:
Cody , thanks for the encouragement . When I took it apart it all came back to me. I had factory service manual to guide me and provide specifics. I did change both synchros , you were right , the slots were beat to hell . No wonder I could not down shift into second without rev matching. Interestingly , book tells you that first and second have a different size slots but the new one was not either size. I put them in anyway and thing is working like its brand new . Tomorrow Im off to smog check and when that is done next transmission is already apart waiting for new synchros ..............

Out of curiosity... did you order the synchros from a website or at the dealer? My dealer never has anything in stock...

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PostPosted: Mon Nov 11, 2013 11:45 pm 
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jankoelbola wrote:
Out of curiosity... did you order the synchros from a website or at the dealer? My dealer never has anything in stock...


I bought them in Hungary when I was there this summer. They produced Mk2/3 till 2002 so parts for them are easy to get and reasonably priced. I was actually ordering parts for my Mk1 transmissions, since they are unobtainable in the US any longer, but the parts guy must of misunderstood me and ordered 6 synchros for Mk2/3. I took them anyway since I have two transmissions , one on my Mk2 Gti and one on my Mk4 Metro, that already required rev matching when down shifting into second. Since then I obtained third one in need of a rebuild and that's the one waiting on my table to receive new synchros. The parts guy did get me the new 1st and 2nd gear synchros for Mk1 so I am in trans rebuilding mode right now.


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PostPosted: Tue Nov 12, 2013 12:08 am 
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The genuine Suzuki syncro rings for 1st and 2nd gear have 8.2 and 9.6mm keyslots respectively, the aftermarket rings usually have an 8.7mm slot for both 1st and 2nd, in theory the wider slot on 1st could cause a blocked shift earlier but in reality they work fine.


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PostPosted: Tue Nov 12, 2013 1:39 am 
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Dattman wrote:
The genuine Suzuki syncro rings for 1st and 2nd gear have 8.2 and 9.6mm keyslots respectively, the aftermarket rings usually have an 8.7mm slot for both 1st and 2nd, in theory the wider slot on 1st could cause a blocked shift earlier but in reality they work fine.


You are absolutely right , that's what my service manual lists too ,but it seems Suzuki decided to just make one size fits all like aftermarket because all the synchros I got were OEM as you can see


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PostPosted: Tue Nov 12, 2013 2:30 am 
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Well that is interesting as the 24431-63B20 is definitely 2nd gear syncro, the keyslots were not 9.6mm???


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PostPosted: Tue Nov 12, 2013 2:36 am 
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Nope , they were 8.7mm just like you mentioned. I used that second gear synchro for the first gear too , so now I have two second ger synchros in my transmission. I did take the car around the block few times and everything is working as new so it must not be a problem. =)

I guess time will tell


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PostPosted: Tue Nov 12, 2013 9:41 am 
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Let's see a pic of your worn parts for comparison.


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PostPosted: Tue Nov 12, 2013 12:07 pm 
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JamalSpelling wrote:
Let's see a pic of your worn parts for comparison.


Here they are , 1st on a top , 2nd in the middle , new replacement synchro on the bottom.

And I forgot to mention in all the previous posts, the synchros were not actually worn out , they were well within the specs even after 200Kmil other then slots being destroyed. First 115Kmil probably with Sta Lube 75-90W , at least it smelled like it , rest of it with Synchromesh. At 115Kmil when I got the car it already wasn't downshifting but I'm so used to rev matching that I do it in all my cars now even if they have good second (even in my Aerio/Liana) and the only reason for this repair is the damn smog check.


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