Dismantle and Re-Assemble All the Synchronizing Devices

Remove the entire input and output shaft, refer to Removing and Installing Complete Drive and Output Shafts





Pull off the shift arms for 1st/2nd and 3rd/4th gear.
Remove special tool 23 2 250.





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





Clamp gear set in a vise fitted with soft jaws on the output shaft.
Pull off 5th/reverse gear operating sleeve.

Caution: Loose thrust pieces, balls and springs.

Remove circlip (4) and spacer (5).

Installation:
Replace circlip (4).





Shift the operating sleeve for 1st/2nd gear towards 2nd gear.
Place contact surfaces of open tool on the 1st gear wheel.
Pull off the guide sleeve, reverse gear wheel with synchromesh ring, pin bearing and bearing bush, 1st gear wheel and thrust washer from the output shaft.





Pull off the needle bearing, synchromesh ring, intermediate ring and outer race.





Pull off the operating sleeve for the 1st/2nd gear.

Caution: Loose thrust pieces, balls and springs.

Lift out circlip (1).
Take off spacer (2).

Installation:
Replace circlip (1).





Place contact surfaces of open tool on the 2nd gear wheel.
Pull off the guide sleeve, 2nd gear wheel with synchronizing device and pin bearing from the output shaft.





Assembling Gear Set: Place on the pin bearing and 2nd gear wheel with the recesses facing upwards.





Install synchronization.
Consisting of: Place the inner race (1), intermediate ring (2) with drives (3) in the recesses of the 1st gear wheel and synchromesh ring (4).





Check the synchronizing device for the 2nd gear for wear.
Measure distance X between the gear and synchromesh ring. In so doing, press down uniformly on the synchromesh ring by hand.
Specification: at least 0.9 mm
Actual new part distance: 1.1 - 1.6 mm.
When replacing, all three parts must be replaced at one time.





Heat guide sleeve to about 80°C with a hot air blower.
Mount the guide sleeve with the long shoulder facing the 2nd gear.
When mounting, make sure that dogs (5) of the inner race are aligned with openings (6) in the gear.
In addition, dogs (7) on the synchromesh ring must engage in grooves (8) of the guide sleeve.





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





Install spacer (2).
Insert circlip (1).
The circlip must seat in the groove without play; if necessary replace spacer (1).
Spacers are available in different thicknesses in steps from 1.8 to 2.05 mm.





Insert 3 thrust pieces (1) and 3 springs (2) into opening of guide sleeve.





Place the operating sleeve for the 1st/2nd gear with the flat side facing upwards or the slanted side facing the 2nd gear wheel.
The three set-back or opened teeth must point to the springs.





Tilt thrust pieces (1) one by one out of the operating sleeve, 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.
Pull the operating sleeve upwards uniformly as far as the lock (neutral position).





Check the synchronizing device for the 1st gear for wear.
Measure distance X between the gear and synchromesh ring. In so doing, press down uniformly on the synchromesh ring by hand.
Specification: at least 0.9 mm Actual new part distance: 1.1 - 1.6 mm.
When replacing, all three parts must be replaced at one time.





Install synchromesh ring (1), intermediate ring (2), and inner race (3) with dogs (4) in openings (5) of the guide sleeve.





Mount needle bearing.
Place 1st gear wheel with grooves (6) facing the lugs (7).





Heat thrust washer (9) and bearing sleeve (8) to about 80°C with a hot air blower and install then on the output shaft, pressing on if necessary.
Use special tool 23 1 290 for thrust washer.
Use special tool 33 1 342 for bearing sleeve.





Inspect reverse gear synchronization for wear.
Measure distance X between the gear and synchromesh ring. In so doing, press down uniformly on the synchromesh ring by hand.
Specification: at least 0.5 mm
Actual new part distance: 0.7 - 1.15 mm.





Mount the needle bearing and reverse gear.





Place the reverse gear synchromesh ring on the reverse gear cone.
Heat the 5th/reverse gear guide sleeve to about 80°C with a hot air blower and install it on the output shaft with conical end (1) facing up; if necessary press on to fit tight with special tool 33 1 342.
Make sure that dogs (3) engage in opening (2).





Install spacer (5) and circlip (4).
Circlip (4) must seat in the groove without play; replace spacer if necessary.
Spacers are available in different thicknesses in steps from 3.6 to 4.0 mm.
Knock in the circlip slightly.





Install 3 pressure pieces (1) and 3 pressure springs (2) in the recess of the guide sleeve.





Install the operating sleeve with shouldered end (1) facing the reverse gear.
The three set-back or opened teeth must point to the springs.





Tilt thrust pieces (1) one by one out of the operating sleeve, far enough that balls (3) can be placed on the springs. Press balls (3) in and simultaneously push 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).





Check the synchronizing device for the 5th gear for wear.
Measure distance X between the gear and synchromesh ring. In so doing, press down uniformly on the synchromesh ring by hand.
Specification: at least 0.75 mm
Actual new part distance: 0.95 - 1.35 mm.





Install synchromesh ring.
Fit the pin bearing and input shaft with 5th gear wheel.





Layshaft: Replace the synchronizing device for the 3rd/4th gear.
Place special tool 23 2 310 at the 3rd gear wheel.
Separate the inner bearing race (1), thrust washer, 4th gear wheel with pin bearing, synchronizing device and 3rd gear wheel with pin bearing from the layshaft.





Assembling: Check the synchronizing device for the 3rd/4th gear for wear.
Measure distance X between the gear and synchromesh ring. In so doing, press down uniformly on the synchromesh ring by hand.
Specification: at least 0.75 mm
Actual new part distance: 0.95 - 1.35 mm.





Fit the pin bearing and 4th gear wheel.





Pull the operating sleeve for the 3rd/4th gear from the guide sleeve.

Caution: Loose balls, springs and thrust pieces.





Place the synchromesh ring on the taper for the 3rd gear wheel.
Heat the guide sleeve for the 3rd/4th gear up to approx. 80°C (hot air blower).
Install the guide sleeve with long shoulder (1) facing the 3rd gear.
When installing, make sure that dogs (2) are aligned with the openings in the guide sleeve.





If necessary, press the guide sleeve on to fit tight with help of special tool 23 1 290.





Heat bearing inner race (3) to about 80°C with a hot air blower and install it on the layshaft.
If necessary, press it on to fit tight with help of special tool 33 1 342.





Insert 3 thrust pieces (1) and 3 springs (2) into opening of guide sleeve.





Fit the operating sleeve for the 3rd/4th gear with the offset side (3) facing upwards.
The three set-back or opened teeth must point to the springs.





Tilt thrust pieces (1) one by one out of the operating sleeve, 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 4th gear synchromesh ring (4) into the guide sleeve openings.
Pull the operating sleeve upwards uniformly as far as the lock (neutral position).





Fit the pin bearing and 4th gear wheel.

Caution: Needle bearings are selected by the manufacturers according to certain tolerances and have a green colour code.

Do not mix up with other needle bearings.





Heat thrust washer (2) and bearing inner race (1) to about 80°C with a hot air blower and install on the layshaft with shoulder (3) facing down.

If necessary, press them on to fit tight with help of special tool 23 1 160.