Hi

I have 99 with 4.0L OHV. I searched and researched replacing the synchronizer and thought I would share some observations.

1) I used a Doorman part: Part Number: 5530-05055033 It came with an alignment tool, but it is the wrong tool.
2) The sensor bolts on the new part are cheap metal, I re-used the original bolts after I broke one during torquing to spec. In retrospect I should have bought OEM.
3) On dis-assembly I looked at the position before taking the synchronizer out, actually put the alignment tool on it and it went on. That gave me confidence that the tool was correct and I was at TDC.
4) On installation I had to insert the synchronizer part way in before putting the alignment tool on because of clearance issues. That made it more difficult to get the tool on.
5) I was getting random P0340 codes. but in testing the sensor seemed okay. The synchronizer is worn, but also seems okay. I also replaced the coil pack because I getting random codes for that too.

All seems fine.

Below are the pictures of the alignment tools. The Black one with the big arrow is what came with the Doorman part.

 

Do you think you could have done the job without the alignment tool?

 

No, because as you insert the synchronizer the shaft rotates, so the Tool really helps you know where you are once the part is all the way in. I guess you could take pictures of the one being removed and then when you drop the new one in see it it looks like the same position. But they only way to know you got it right for sure is to put it all back together....