S5D 320Z Transmission
Disassembling And Assembling All Synchronizing Mechanisms
Remove drive and output shafts.
Detach 1st/2nd and 3rd/4th gear shift arms.
Remove special tool 23 2 250.
Detach drive shaft (1), synchronizer ring (2) and roller bearing (3).
Grip gear train at output shaft (use protective vise jaws).
Detach 5th/reverse gear sliding sleeve.
Caution: Loose thrust pieces, balls and springs.
Remove retaining ring (4) and spacer (5).
Installation:
Replace retaining ring (4).
Move 1st/2nd gear sliding sleeve in direction of 2nd gear.
Position press-off supports on 1st gear wheel.
Press following parts off output shaft:
^ Guide sleeve
^ Reverse gear wheel with synchronizer ring
^ Needle bearing
^ Bearing sleeve
^ 1st gear wheel
^ Thrust washer
Pull off following parts:
^ Needle bearing
^ Synchronizer ring
^ Intermediate ring
^ Outer race
Detach 1st/2nd gear sliding sleeve.
Caution: Loose thrust pieces, balls and springs.
Lever out retaining ring (1).
Remove spacer (2).
Installation:
Replace retaining ring (1).
Position press-off supports on 2nd gear wheel.
Press guide sleeve, 2nd gear wheel with synchronizing mechanism and needle bearings off output shaft.
Assembling gear train:
Fit needle bearings and 2 gear wheel with recesses facing upwards.
Attach synchronizing mechanism.
Consisting of: Place the inner race (1), intermediate ring (2) with drives (3) in the recesses of the 1st gearwheel and synchronizer ring (4).
Check 2nd gear synchronizing mechanism for wear.
Measure distance X between gear wheel and synchronizer ring. In so doing, press down uniformly on the synchronizer 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 approximately 80°C (hot air blower).
Fit guide sleeve with long collar facing 2nd gear wheel.
When fitting, make sure driver lugs (5) of inner race are flush with recesses (6) on gear wheel.
In addition, driver lugs (7) on synchronizer ring must engage in grooves (8) of guide sleeve.
Press on guide sleeve with special tool 23 1 290 until firmly seated.
Install spacer (2).
Install retaining ring (1).
Retaining ring must be seated without play in groove; if necessary, replace spacer (1).
Spacers are available in different thicknesses Sizes from 1.8 ... 2.05 mm.
Insert 3 thrust pieces (1) and 3 pressure springs (2) in recess in guide sleeve.
Fit 1st/2nd gear sliding sleeve with flat side facing upwards or with angled side facing 2nd gearwheel.
The three set-back or opened teeth must point to the springs.
Tilt thrust pieces (1) individually as far out of sliding sleeve until balls (3) can be placed on pressure springs.
Press balls (3) inwards. Simultaneously press thrust pieces into sliding sleeve.
Pull sliding sleeve uniformly upwards up to lock (neutral setting).
Check 1st gear synchronizing mechanism for wear.
Measure distance X between gear wheel and synchronizer ring. In so doing, press down uniformly on the synchronizer 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.
Place synchronizer ring (1), intermediate ring (2) and inner race (3) with driver lugs (4) in recesses (5) in guide sleeve.
Fit needle bearing. Fit 1st gear wheel with grooves (6) facing driver lugs (7).
Heat thrust washer (9) and bearing bush (8) to approximately 80°C (hot air blower) and attach to output shaft, press on if necessary.
Thrust washer with special tool 23 1 290.
Bearing bush with special tool 33 1 342.
Check reverse gear synchronizing mechanism for wear.
Measure distance X between gear wheel and synchronizer ring. In so doing, press down uniformly on the synchronizer ring by hand.
Specification: at least 0.5 mm
Actual new part distance: 0.7 ... 1.15 mm.
Fit needle bearing and reverse gear wheel.
Fit reverse gear synchronizer ring on reverse gear taper.
Heat 5th/reverse gear guide sleeve to approximately 80°C (hot air blower).
Fit output shaft with tapered end (1) facing upwards; if necessary, press on with special tool 33 1 342 until firmly seated.
Make sure driver lugs (3) engage in recess (2).
Insert spacer (5) and retaining ring (4).
Retaining ring (4) must be seated without play in groove; if necessary, replace spacer.
Spacers are available in different thicknesses In sizes from 3.6 ... 4.0 mm.
Gently knock retaining ring inwards.
Insert 3 thrust pieces (1) and 3 pressure springs (2) in recess in guide sleeve.
Fit sliding sleeve with stepped side (1) facing reverse gear wheel.
The three set-back or opened teeth must point to the springs.
Tilt thrust pieces (1) individually as far out of sliding sleeve until balls (3) can be placed on pressure springs.
Press balls (3) inwards. Simultaneously press thrust pieces into sliding sleeve.
Insert 5th gear synchronizer ring in sliding sleeve.
Pull sliding sleeve uniformly upwards up to lock (neutral setting).
Check 5th gear synchronizing mechanism for wear.
Measure distance X between gear wheel and synchronizer ring. In so doing, press down uniformly on the synchronizer ring by hand.
Specification: at least 0.75 mm
Actual new part distance: 0.95 ... 1.35 mm.
Insert synchronizer ring.
Attach needle bearing and drive shaft to 5th gear wheel.
Countershaft:
Replace 3rd/4th gear synchronizing mechanism.
Fit special tool 23 2 310 on 3rd gearwheel.
Press bearing inner race (1), thrust washer, 4th gear wheel with needle bearing, synchronizing mechanism and 3rd gearwheel with needle bearing off countershaft.
Assembling: Check 3rd/4th gear synchronizing mechanism for wear.
Measure distance X between gear wheel and synchronizer ring. In so doing, press down uniformly on the synchronizer ring by hand.
Specification: at least 0.75 mm
Actual new part distance: 0.95 ... 1.35 mm.
Fit needle bearings and 3th gearwheel.
Pull 3rd/4th sliding sleeve off guide sleeve.
Caution: Loose balls, springs and thrust pieces.
Fit synchronizer ring on 3rd gear taper.
Heat 3rd/4th gear guide sleeve to approximately 80°C (hot air blower). Fit guide sleeve with long collar (1) facing 3rd gear wheel.
When fitting, make sure driver lugs (2) are flush with recesses on 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 approximately 80°C (hot air blower) and attach to countershaft.
If necessary, press it on to fit tight with help of special tool 33 1 342.
Insert 3 thrust pieces (1) and 3 pressure springs (2) in recess in guide sleeve.
Fit 3rd/4th gear sliding sleeve with stepped side (3) facing upwards.
The three set-back or opened teeth must point to the springs.
Tilt thrust pieces (1) individually as far out of sliding sleeve until balls (3) can be placed on pressure springs.
Press balls (3) inwards. Simultaneously press thrust pieces into sliding sleeve.
Insert 4th gear synchronizer ring (4) in recesses in guide sleeve.
Pull sliding sleeve uniformly upwards up to lock (neutral setting).
Fit needle bearing and 4th gear wheel.
Caution: The needle bearing has been selected by the manufacturer in accordance with a specific tolerance and is green in color.
Do not mix up with other needle bearings.
Heat thrust washer (2) and bearing inner race (1) to approximately 80°C (hot air blower) and attach to countershaft with collar (3) facing downwards. If necessary, press them on to fit tight with help of special tool 231 160.