Replacing Output Shaft
Replacing Output Shaft
- Output Shaft Removed -
Pull off input shaft (1), synchromesh ring (2) and needle bearing (3).
Note: Synchronization: To avoid mixing up synchromesh rings, it is recommend to mark synchromesh rings and corresponding gear wheels when disassembling the output shaft.
Pull off thrust washer (4), 5th gear (5), synchromesh ring (6) and needle bearing (7)
Transmission 260/6:
Pull ball bearing inner race (1) off of the output shaft with Special Tool 00 7 500
Transmission 260/6
Pull off 5th gear wheel and synchromesh ring
Take off thrust washer (2) and ball (3)
Pull off needle bearing.
Lift out circlip (8)
Remove spacer (9)
Installation
Always replace circlip
Installation
Adjust play between circlip and guide sleeve to 0...0.09 mm (0 to 0.0035")
Press 2nd gear bearing sleeve, 3rd gear synchromesh ring and guiding sleeve with sliding sleeve off of output shaft with Special Tool 23 2 080
Pressing off force
Note: Circlip (10) must be removed before pressing off the first gear wheel.
Installation
Always replace circlip
Press off 1st gear wheel and guide as well as operating sleeve with Special Tool 23 1 490.
Take off needle bearing pressing off force
Note: Circlip (11) must be removed before pressing off the reverse gear wheel
Installation
Always replace circlip
Press off guide as well as operating sleeve and reverse gear, wheel with Special Tool 23 2 080, with the bottom end facing the gear wheel.
Take off needle bearing
Pressing off force
Assembling:
Note: Check wear of synchromesh rings before assembling
Install needle bearing reverse gear wheel and synchromesh ring.
Slide guide and operating sleeve on splines of the output shaft.
Transmission 260/6 and 260/5 or 260 Sport: Shouldered end of operating sleeve faces reverse gear wheel or for version with 1 groove, 5th gear wheel.
Press on guide sleeve to fit tight with Special Tool 23 1 290
Pressing on force
Note: Make sure tabs on synchromesh ring are aligned with openings in the guide sleeve while pressing on.
Move operating sleeve in direction of reverse gear wheel.
Adjust guide sleeve to be without play with circlip (11).
Circlip are available from parts in different thickness between 1.7 and 2.0 mm (0.067 and 0.079)
Install circlip (11).
Install needle bearing, 1st gear wheel and synchromesh ring.
Slide guide and operating sleeves on the splines of the output shaft.
Transmission 260/6 and 260/5 or 260 Sport: Shouldered end of operating sleeve faces the 1st gear wheel or, for version with 2 grooves, 2nd gear wheel.
Press on guide sleeve to fit tight with Special Tools 23 1 290.
Pressing on force
Note: Make sure tabs on synchromesh ring are aligned with openings in the guide sleeve while pressing on.
Move operating sleeve in direction of the 1st gear wheel.
Adjust guide sleeve to remove all play.
Circlips are available from parts in different thicknesses between 1.7 and 2.0 mm (0.067 and 0.079").
Install circlip (10).
Install needle bearing, synchromesh ring and 2nd gear wheel.
Note: Collar for bearing sleeve on the output shaft must protrude slightly if necessary, check whether circlip seats correctly.
Heat bearing sleeve to about 80° C (175°F) with a hot air blower and install on the output shaft.
Transmission 260/6 and 260/5 or 260 Sport: Install ball (3) and thrust washer (2) with the opening facing ball (3).
Transmission 260/6 and 260 Sport:
Heat bearing sleeve (4) 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 sleeve on splines with the long collar facing the 3rd gear wheel.
260/5 since 6.85 or 260 Sport:
Shouldered end of operating sleeves faces the 3rd gear wheel or for version with 3 grooves the 4th gear wheel.
260/6
Groove for shift for is off-center.
Wide flat spot on operating sleeve faces the 3rd gear wheel.
Press on guide sleeve to fit tight with Special Tool 23 1 290
Note: Make sure that tabs on synchromesh ring are aligned
with openings in the guide sleeve while pressing on.
Install shim and circlip.
Pressing on force
Pull off thrust washer (4), 5th gear wheel (5), synchromesh ring (6) and needle bearing (7).
Transmission 260/6:
Slide needle bearing on output shaft.
Insert ball(3).
Install thrust washer (2) with opening facing the ball.
Install synchromesh ring and 5th gear wheel.
Transmission 260/6
Heat ball bearing inner race to about 80° C (175°F) with a hot air blower and install on the output shaft