Output Shaft

Output Shaft





Disassembly





1. CAUTION: Handle the dual synchronizer parts with care.

Remove the ball bearing and the fourth gear wheel.
1. Remove the small snap-ring.
2. Install the snap-ring.
3. Using a standard puller, remove the ball bearing.
4. Remove the fourth gear wheel together with the synchronizer ring.





2. Remove third and fourth gear synchronizer unit.
1. Remove the snap-ring.
2. Remove the gear synchronizer, the third and fourth gear synchronizer unit and the third gear wheel.





3. Remove the third gear synchronizer ring.
1. Synchronizer ring.
2. Gear wheel (third gear)





4. NOTE: The dual synchronizer as shown is used in case off servicing.

Disassemble the third gear synchronizer unit.
1. Outer synchronizer ring
2. Synchronizer cone
3. Inner synchronizer ring
4. Gear wheel (third gear)





5. Remove the second gear wheel together with the synchronizer unit.
1. Closed retaining ring
2. Half-round snap rings
3. Gear wheel (second gear)
4. Inner synchronizer ring
5. Synchronizer cone
6. Outer synchronizer ring





6. NOTE: Remove the synchronizer unit and the first gear wheel together.

Remove the first gear wheel and the reverse gear wheel together with the gear synchronizer and the synchronizer unit.
1. Remove the snap-ring.
2. Remove the first/second gear synchronizer together with the reverse gear wheel.
3. Outer synchronizer ring
4. Synchronizer cone
5. Inner synchronizer ring
6. Gear wheel (first gear)





7. CAUTION: Mark the installation position of the selector ring in relation to the gear synchronizer hub.

Disassemble the synchronizer hub.
1. Selector ring
2. Synchronizer spring
3. Synchronizer lock
4. Gear synchronizer hub





8. NOTE: Insert a pressure piece into oil the thrower bore.

Using the special tools, remove the output shaft bearing cone.
1. Remove the snap-ring. Position the special tool 307-217 below of the bearing cone.
2. Remove the bearing cone.

Assembly

CAUTION: Immerse the dual synchronizer units in a bath of transmission fluid prior to installation.

1. Carefully clean and check all running surfaces and coat them with Manual transmission fluid before reassembly.





2. NOTE: Install a new snap ring.

Install the output shaft bearing cone. Evenly heat the bearing cone to approximately 80�C and slide it onto the output shaft.
- Install the snap-ring.





3. NOTE: Marking of selector ring installation position in relation to gear synchronizer hub.

Assemble the gear synchronizer.
1. Gear synchronizer hub
2. Install the selector ring onto gear synchronizer hub.
3. Insert the synchronizer lock.
4. Insert the synchronizer spring.





4. NOTE: Install a new snap ring.

Install the first gear and reverse gear wheel onto the output shaft together with the gear synchronizer and the synchronizer unit.
1. Gear wheel (first gear)
2. Inner synchronizer ring
3. Synchronizer cone
4. Outer synchronizer ring
5. First/second gear synchronizer with reverse gear wheel
6. Snap-ring





5. NOTE: Re-assemble synchronizer unit prior to installation.

NOTE: Install new half round snap rings.

Install the second gear wheel onto the output shaft together with the synchronizer unit.
1. Outer synchronizer ring
2. Synchronizer cone
3. Inner synchronizer ring
4. Gear wheel (second gear)
5. Half-round snap-rings
6. Closed retaining ring





6. NOTE: The dual synchronizer as shown is used in case of servicing.

Assemble the third gear synchronizer unit.
1. Gear wheel (third gear)
2. Inner synchronizer ring
3. Synchronizer cone
4. Outer synchronizer ring





7. Install the third gear synchronizer ring.
1. Synchronizer ring.
2. Gear wheel (third gear)





8. NOTE: Install the selector ring with annular groove facing downwards and small hub collar facing upwards.

NOTE: Install a new snap ring.

Install the third/fourth gear synchronizer unit
1. Install the gear synchronizer, the third/fourth gear synchronizer unit and the third gear wheel.
2. Install the snap-ring.





9. NOTE: Install the ball bearing with annular groove facing outwards.

NOTE: Install a new snap ring.

Install the fourth gear wheel and the ball bearing.
1. Install the synchronizer ring together with the fourth gear wheel.
2. Using a press and a suitable tube, press on the ball bearing.
- Install the snap-ring.