Replacing Output Shaft

Replacing output shaft

-output shaft removed-






Pull off input shaft (1), synchromesh ring (2) and needle bearing (3)

Note:To avoid mixing up the synchromesh rings while disassembling the output shaft it is recommended to mark the synchromesh rings for a pertinent gear wheel.







pull off 5th gear wheel (4) synchromesh ring (5) and needle bearing (6).







Lift out circlip (7)
take off spacer (8).

Installation

Always replace the circlip.

Installation






Adjust play between the circlip and guide sleeve to 0.. 0.09mm (0 to 0.0035").






Press off 3rd gear wheel guide and operating sleeves with Special Tool 23 1 490
Take off needle bearing
Press-off force






Press off bearing sleeve and 2nd gear wheel with Special Tool 23 1 490
Remove needle bearing and synchromesh ring.







Note:circlip (10) must be removed before pressing off the 1st gear wheel.

Installation:

Always replace the circlip.






Press off 1st gear wheel guide and operating sleeves with Special tool 23 1 490
Take off needle bearing
Pressing off force






Important:

Circlip (11) must be removed prior to pressing off the reverse gear wheel

Installation:

Always replace the circlip







Place output shaft next to the collar.







Press guide and operating sleeves as well as reverse gear wheel off of the output shaft.
Take off needle bearing
Pressing off force.







Assembling:

Note:
Check wear of synchromesh rings
prior to assembling.
Install needle bearing, reverse gear
wheel and synchromesh ring (only for version
with synchronized reverse gear).
Insert guide and operating sleeves on splines of the output shaft.

Note:
Version with 3 identification Grooves
Grooves must face the 5th gear wheel







Important
version without synchronized reverse gear:
Retainer (1) in the guide sleeve faces the reverse gear wheel.







Press on guide sleeve to fit tight with
special tool 23 1 290
pressing on force.

Important


Make sure that tabs on the synchromesh ring are aligned with openings in the guide sleeve while pressing on.







Shift operating sleeve in direction of the reverse gear wheel.
adjust guide sleeve to be without play with circlip (11).
Circlips are available from parts in different thickness from 1.7 to 2.0 mm (0.067 to 0.079") install circlip (11).






Install needle bearing, 1st gear wheel and synchromesh ring.
slide guide and operating sleeves on splines of the output shaft.

Shouldered operating sleeve version:
Shouldered end faces 2nd gear wheel.

Version with Identification groove.
groove faces 1st gear wheel.







Press on guide sleeve to fit tight with
special tool 23 1 290
pressing on force

Important:

Make sure that tabs on the synchromesh ring are aligned with openings in the guide sleeve while pressing on.







Shift operating sleeve in direction of the 1st gear wheel
Adjust guide sleeve to be without play circlips are available from parts in different thickness from 1.7 to 2.0mm (0.067 to 0.079).
Install circlip (10)






Install needle clearing synchromesh
ring and 2nd gear wheel.

Important:

Collar for the bearing sleeve on the output shaft must protrude
slightly.
If necessary, check circlip (10) for correct seating.







Heat bearing sleeve to about 80 ° C
(175 ° F) with a hot air blower and install on the output shaft.







Version with Thrust Washer:
Install thrust washer (1) and ball (2).
Heat bearing sleeve (3) Without collar to about 80 ° C (175 °F) with a hot
air blower and install on the output shaft.







Install needle bearing 3rd gear wheel
and synchromesh ring
install guide and operating sleeves on the splines with
the groove facing the 4th gear wheel

Version with 2 Identification grooves:
Grooves face the 3rd gear wheel.

Press on guide sleeve to fit tight with Special tool 23 1 290







Important:

Make sure that tabs on synchromesh ring are aligned with openings in the guide sleeve while pressing on

Install spacer and circlip.

Pressing on force.