I'm trying to remove the 5th gear from the cluster shaft on a '95 T-5. I am stuck on the synchronizer hub. It won't come off.
I drove the pin out of the 5th gear shifter fork, and I also removed the external C-clip from the end of the cluster shaft. This allowed me to remove, in order, (1) an internally splined washer which locks into the fine splines on the tip of the cluster shaft and which retains (2) a black conical washer which fits inside of (3) a brass "blocker" ring, which fits inside of (4) the synchronizer sleeve. Also removed are the three "inserts" (the little metal rectangles that look like tiny cars, that fit into the gaps of the synchronizer hub) and outermost of the two synchronizer springs. Also, the shifter fork necessarily came off with the synchronizer sleeve. But the inner ring, the synchronizer hub, will not come off.
(You can see most of these parts in p. 16 of Chris Neighbor's PDF at
So that's my question. Why won't that synchronizer hub come off? What's the trick?
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