Assembling an operating sleeve
How to compress the six detent springs

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Using the 3rd-4th operating sleeve and synchro sleeve as an example ...

Place the operating sleeve on a timber surface, selector fork groove downwards. Place a 50mm diameter wooden circular block inside the operating sleeve (to prevent the synchro sleeve going too far into the operating sleeve.)

Refer first to the guide on how the mate these two parts correctly.

Slide the synchro sleeve inside the operating sleeve, with the 3rd gear relieved tooth visible from above, and lined up with either one one of the two plunger holes. 

Lift the synchro sleeve slightly or enough to insert the six selected springs into their blind holes. Then insert the six detent balls against the six springs - each ball should sit in place. The balls will be be projecting from the synchro sleeve, holding the synchro sleeve up, as shown in the photo.

Take a suitable stainless steel (light duty) worm drive hose clamp and place the clamp over the six protruding balls, with the pressed metal worm drive screw housing centred on one of the six balls. Tighten the worm drive screw with a socket wrench, until the clamp is tight. Then slacken the screw a very small amount. Then, using a leather glove or other protection, press down on the synchro sleeve with sufficent pressure to force the balls into their holes, compressing the six springs so that the synchro sleeve will slide fully into the operating sleeve. At some point after the six balls have disappeared below the top of the operating sleeve, remove the wooden block and then press the synchro sleeve further into the operating sleeve until the balls are able to pop into the round groove that is machined in the inside face of the operating sleeve. At this point, the detent springs will enable to the two parts to be handled as one.

The assembled sleeves can now be mounted on the mainshaft when required.

hoseclamp ready

hose clamp on