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W116 (1972-1980, petrol) W126 (1979-1991, petrol) W140 (1991-1998) W220 (1998-2005)
  • Main
  • S-Class
  • W116 (1972-1980)
  • Transmission
  • Clutch and cardan
  • Disassembly and assembly of synchronizer of manual transmission

Disassembly and assembly of synchronizer of manual transmission (Mercedes-Benz S-Class W116)

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Wrap the synchronizer coupling with a rag and squeeze it out of the hub together with the driver. Check the wear of all parts. Remove the locking rings and drivers from the synchronizer coupling. Check their condition. The locking rings are different in diameter and must match the diameter of the synchronizer coupling. Fig. 199 shows the parts of both synchronizer couplings.

Fig. 199. Synchronizer clutch parts.

Fig. 199. Synchronizer clutch parts.
1 - 3/4 gear synchronizer clutch,
2 - locking ring,
3 - leash,
4 - 1/2 gear synchronizer clutch,
5 - locking ring,
6 - leash.


When assembling the synchronizer of the first and second gears, make sure that the flange on the synchronizer sleeve and the narrow part of the synchronizer hub are directed towards the first gear (indicated by arrows in Fig. 200). Install the third and fourth gear synchronizer sleeve on the hub so that the groove on the sleeve and the wide part of the hub are located on the same side (arrow in Fig. 200). The enclosing side of one locking ring is adjacent to seven leashes. The leashes are placed one after another on the locking rings and the synchronizer hub is pushed into the synchronizer clutch.



Fig. 200. Sectional view of synchronizers with locking rings for first and second gears (left) and…

Fig. 200. Sectional view of synchronizers with locking rings for first and second gears (left) and third and fourth gears (right). Gears are indicated by arrows.


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S-Class W116 / Clutch and cardan
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W220 (1998-2005) 
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W140 (1991-1998) 
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W126 (1979-1991, petrol) 
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W116 (1972-1980, petrol) 
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  • 8-cylinder V8 engine
  • 6-cylinder I6 engine
  • Cooling and lubrication system
  • Power system (carburetor)
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  • Ignition system
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  • Car gearbox
  • Chassis
  • Front suspension
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