240D manual transmission synchros (pics)
 

I did not find many pics of the inside of these 716.210 4 speed manual transmission. I had to replace 2 brass synchroniser rings: 3rd and 4Th speed rings were broken. I bought the car like this from the previous owner. The tranny was still working fine (!) with the "double clutch" method (second to third and third to fourth). First gear to second was OK...The key was to replace the synchros and after a road test, everything is now perfect!:) Like a new one! Cost for each synchro is $50 CDN.

HDen

:bowrofl: :bowrofl:
WE ARE NOT WORTHY. How hard was it to disassemble the tranny? Just take off the end piece? Did you have to pull the gears to get to the synchros? I have found zero info on rebuilding these. My 1st to 2nd is shot.

Fifty canadian for a new syncro ring is not bad. There is some coverage in the reasonable priced haynes manual on standards I think. Although I do not think you really require a manual to change one. It is fairly straightforward on these I believe. I just had a look and there is probably enough information in that low cost manual to get you by as well if needed.

The Real McCoy can be downloaded here:

The 1st to 2nd synchro ring is located "close" to the rear cover of the tranny. See pic from my first post. The 2 rings I had to change were at "the bottom" of the box when we look from the rear end. That's why I had to remove the whole shaft. I don't think you need to remove the shaft, but i'm not sure :confused: Just remove the gears one by one in order to get to the brass synchros. A few snap rings to be removed. Make sure the get new "clips" that retains the synchro to the gear (Item #109 and #127)

It's not hard to dismantle the tranny, but I took my time! It's winter here and I don't need the car. In order to remove the shaft completly, I had to remove the cover in the housing (pic Housing1) and also the upper shaft and the snap rings (pic Housing2). The lower shaft (countershaft) didn't have to be removed.

Maybe your job can be done without removing the tranny from the car?? Just remove the rear cover etc...That would be relatively "easy" but not sure if you will have enough room to work. This way, the slave cylinder may stay in place and you will not have to bleed the system. Good luck!!

Nice work.

My 115 has a crapped-out 1-2 synchronizer and, I have another 4-speed (spare) with a trashed final drive spline and spider. One of these days...

Cool thread. Thanks. My 2nd into 3rd is pretty bad. One of these days I hope to be able to get into it and do this stuff myself.

- Peter.

now that is a whompin pdf

oh and look at all the goodies in the parent directory.... i am officially leeching as we speak. wget -r is a wonderful thing

Don't go there...

Great pics. Do you need a puller to remove the gears? Is there any special way to realign them when reinstalling or do you just slide everything back on?

No pullers, the gears are mounted on the shaft with splines. A good snap ring plier is required. No need to realign when reinstalling.
HDen

Is it just me, or is there chunks missing on that lower right gear in the second picture?

Does anyone know the price of the plate wear gauge? 115 589 07 23 00

The 3 openings you can see are to accept the brass synchro ring (4th gear). There is also a small needle bearing in the center to receive the left side of the main shaft (pic from the first post).

HDen

Oh my god, you guys are life savers.

I just done a transmission swap in my 300D coupe turbo, and found 2nd gear to be synchro bad :'(

4 speed manual from a 300D

I'll get the Box's part number when the sun is up, but do you guys know the part number of the synchro for 2nd gear please ?