Can any one tell me how you set a synchronizer to TDC #1 cyl? I have no probs with removal just install, any help will be greatly appreciated,

Put the engine on TDC (make sure the cam marker is at 3o'clock)

With the syncronizer in your hand, rotate the gear until a notch lines up with a hole in the side.
Stick a drill bit of something in the hole so the gear doesn't move (I use a rivet head)

Now Slowly slide it in the dizzy hole slightly offset (facing the front of the AC compressor iirc) so it meshes with the gears and forces it to align to the back of the AC compressor.

When you've done fighting the oil pump shaft and it has allowed you to drop it all the way in, get the bracket and clamp it down, If you have it in correctly then you can clamp it down, if not, the notches wont align to the clamp and you'll have to refit it again.

Once in remove the drill bit/rivet.

If your fitting it to an EB/AU engine have a look at this pic.