Detaching and Mounting All Synchronizing Devices

Detaching And Mounting All Synchronizing Devices

- Transmission removed.
- Completely remove input and output shafts.




- Remove gears and shafts with selector rods from special tool 23 2 400.




- Remove selector rods (1).
- Separate layshaft from gears and shafts.




- Remove input shaft, needle bearing (1) and 5th gear synchronizer ring.




- To ease assembly, insert the output shaft in special tool 23 2 400. Pull 5th/reverse gear sliding sleeve (2) oft the guide sleeve.

Caution! Loose thrust pieces, balls and springs.

- Lift out circlip (1).

Installation:
- Replace circlip.




- Rotate the output shaft so that the drive end faces up. Double taper synchronization:
- Remove 1st gearwheel (1), needle bearing (2), synchronizer ring (3), taper ring (4) and friction ring (5) from the output shaft




- Single taper synchronization:
- Remove 1st gearwheel (1), needle bearing (2) and synchronizer ring (3) from the output shaft.




- Lift out circlip (1).
- Pull off 1st/2nd gear sliding sleeve (2). Caution!
- Loose thrust pieces, balls and springs.

Installation:
- Replace circlip (1).




- Separate 2nd gearwheel (2) and guide sleeve (1) from the output shaft by pressing.




- Remove reverse gear wheel, synchronizer ring and guide sleeve (1) from the output shaft with special tool 23 1 490 by pressing.




- Prior to assembling gears and shafts, check all synchronizing devices for wear. For this purpose, determine gap measurement X between synchronizer ring and the corresponding gears.
- Measure near the detent lugs. Uniformly press synchronizer ring in direction of taper.

Gap measurements of the individual gear wheels.
1st/2nd gear 1.3-2.1 mm
3rd 1.1-1.5 mm
4th/5th gear 0.9-1.5 mm
Max. wear limit size 0.8 mm
New condition 1.1-1.7 mm
Max. wear limit size 0.5 mm




- Assembly of gears and shafts:
- Connect needle bearing (1), reverse gearwheel (3) and synchronizer ring (2).

Note: Lightly oil needle bearing (1) and synchronizer ring (2) on bearing surfaces with ATF-oil.




- Heat guide sleeve (1), 5th/reverse gear, to approx. 120 °C (hot air blower) and connect to the output shaft. If necessary, press on with special tool 23 1 290 until tight.

Caution! While pressing on, ensure that the detent lugs (2) catch in the openings in the guide sleeve.




- Install appropriate circlip (1). Circlips are available in Parts Service from 2.0-2.3 mm in increments of 0.05 mm.
- Max. permissible end float X: 0.04 mm.




- Insert 3 thrust pieces (1) with bevels outward and springs (2) in guide sleeve openings.




- Attach sliding sleeve (1) with the orientation groove (2) to the reverse gear wheel (3).




- Tilt thrust pieces (1) out of the operating sleeve separately far enough that balls (3) can be placed on the springs. Push in balls (3) and simultaneously press the thrust pieces into the operating sleeve. Insert 5th gear synchronizer ring into the sliding sleeve. Pull the operating sleeve upwards uniformly as far as the lock (neutral position).




- Rotate the output shaft so that the drive end faces up. Connect needle bearing (1) and 2nd gear wheel (2) to the output shaft.

Note: Coat needle bearing surfaces with ATF-oil.




- Double taper synchronization:

Note: On renewal, the 1st/2nd gear synchronization must be completely renewed.

- Attach taper ring (2), friction ring (3) and synchronizer ring (4) so that the lugs (5) of the friction ring catch in the opening (6) on the 2nd gearwheel (1).
- Lugs (8) on the synchronizer ring (4) catch in the opening (7).




- Heat 1st/2nd gear guide sleeve to approx. 120 °C (hot air blower) and connect to the output shaft. If necessary, press on with special tool 23 1 290 until tight.

Caution! While pressing, ensure that the detent lugs (1) catch in the opening in the guide sleeve.




- Single taper synchronization:
- Position synchronizer ring (1).




- Single taper synchronization:
- Heat 1st/2nd gear guide sleeve to approx. 120° (hot air blower).
- Position the guide sleeve so that the detent lugs (1) point towards the opening (3) of the guide sleeve (2).
- Press guide sleeve (2) with special tool 23 1 290 until secure.
- While pressing, ensure that the detent lugs (1) catch in the opening in the guide sleeve.




- Insert 3 thrust pieces (1) with bevels outward and 3 (pressure) springs (2) in guide sleeve opening.




- Double taper synchronization:
- Position sliding sleeve (1).




- Single taper synchronization:
- Attach sliding sleeve (1) with the orientation groove (2) to the 2nd gear wheel. Lug (3) on the sliding sleeve point towards the middle of the opening (4), or, as the case may be, the teeth with the grooves (5) towards the opening (6) of the sliding blocks.




- Tilt thrust pieces (1) out of the operating sleeve separately far enough that balls (3) can be placed on the springs.
- Push in balls (3) and simultaneously press the thrust pieces into the operating sleeve.




- Insert 1st gear synchronizer ring (1) into the guide sleeve openings.
- Pull the operating sleeve upwards uniformly as far as the lock (neutral position).




- Install appropriate circlip (1). Circlips are available in Parts Service from 2.0-2.3 mm in increments of 0.05 mm.
- Max. permissible end float X: 0.04 mm.




- Double taper synchronization:
- Connect needle bearing (5).
- Install synchronizer ring (6), friction ring (4) and taper ring.
- Position 1st gear wheel.

Caution! Lug (3) must catch in opening (4) and lug (2) must catch in opening (1).

- Coat needle bearing and synchronizer ring on bearing surfaces with ATF-oil.




- Single taper synchronization:
- Connect needle bearing (1).
- Position synchronizer ring (2) with the lugs (3) to the sliding blocks.

Note: Coat needle bearing and synchronizer ring on bearing surfaces with ATF-oil.

- Connect 1st gearwheel (4).




- Connect roller bearing (1), 5th gear synchronizer ring (2) and input shaft to the output shaft (3).

Note: Coat needle bearing and synchronizer ring on bearing surfaces with ATF-oil.

- Lift off input and output shafts from special tool 23 2 400 and lay to the side.




- Layshaft:
- 3rd/4th gear synchronizing device:
- For assembly, insert layshaft in special tool 23 2 400.
- Lift out circlip (1).

Installation:
- Replace circlip (1).




- Hold layshaft in a press.
- Select largest possible support surface on fixed wheel.
- Remove fixed wheel from the layshaft by pressing.




- Remove closing ring (1). For this purpose, bend the 4 tabs outwards with pliers for this purpose.
- Remove supporting ring (2) (two parts) and stop disc (3).

Installation:
- Replace closing ring (1).




- Remove 4th gear wheel (1), synchronizer ring (2) and needle bearing (3).




- Pull 3rd/4th gear sliding sleeve upward.

Caution! Loose thrust pieces, balls and springs.




- Fit countershaft in a press. Press off 3rd gear (1), guide sleeve (2) and bearing bush (3) from the countershaft.




- Prior to assembly, check all synchronizing devices for wear.
- For this purpose, determine gap measurement X between synchronizer ring and the corresponding gears.
- Measure near the detent lugs.
- Uniformly press synchronizer ring in direction of taper.
- Gap measurements of the individual gear wheels.
1st/2nd gear 1.3-2.1 mm
3rd 1.1-1.5 mm
4th/5th gear 0.9-1.5 mm
Max. wear limit size 0.8 mm
New condition 1.1-1.7 mm
Max. wear limit size 0.5 mm




- Connect needle bearing (1), 3rd gear wheel (3) and synchronizer ring (2).

Note: Coat needle bearing and synchronizer ring on bearing surfaces with ATF-oil.




- Heat guide sleeve to approx. 1200 C (hot air blower) and position on the layshaft. Position 3rd/4th gear guide sleeve an press on with special tool 23 1 290 until secure.

Caution! While pressing, ensure that the detent lugs (1) catch in the opening in the guide sleeve.




- Heat inner bearing race (1) to approx. 80°C (hot air blower) and push onto layshaft until limit stop.




- Insert 3 thrust pieces (1) with bevels outward and 3 (pressure) springs (2) in guide sleeve opening.




- Attach sliding sleeve (1) with the orientation groove (2) to the 3rd gear wheel (3).
- The three recessed teeth (4) must point towards the springs (5) / sliding blocks.




- Tilt thrust pieces (1) out of the operating sleeve separately far enough that balls (3) can be placed on the springs. Push in balls (3) and simultaneously press the thrust pieces into the operating sleeve. Insert 3rd gear synchronizer ring into the sliding sleeve. Pull the operating sleeve upwards uniformly as far as the lock (neutral position).




- Connect needle bearing (1), synchronizer ring (2) and 4th gear wheel (3) to the layshaft.

Note: Coat needle bearing and synchronizer ring on bearing surfaces with ATF-oil.




- Slip stop disc (1) over the gearing up to the bearing surface.




- Insert small radius supporting ring (two parts) (1) downwards into the groove.
- If the supporting ring is replaced, the end float must be adjusted.
- Max. end float 0.04 mm.
- Supporting rings from 2.9-3.15 mm in increments of 0.05 mm are available in Parts Service.




- Attach special tool 23 2 410 to the layshaft.
- Clip the closing ring (1) with 4 fastening lugs into the groove (3).




- Heat fixed wheel to approx. 180°C (heating plate). Check with thermometer.
- Position layshaft in a press.
- Place fixed wheel on the layshaft and press firmly into place with special tool 23 1 290.




- Insert circlip (1).




- Connect layshaft together with input and output shafts.
- Attach 3rd/4th gear switch rod (1), 1st/2nd gear switch rod (2) and 5th/reverse switch rod (3).