Gear: Service and Repair

Transmission Assembly:

Legend 1:

Legend 2:

Removal





- Loosen nuts for drive pinion and drive shaft. Place reverse gear shaft or other corresponding shaft in bore of gear housing. Slide on reverse gear II as illustrated and place in 4th.





- Unscrew reverse gear lock plug.

WARNING: Plug is under heavy spring tension. Prevent spring and plug from jumping away when unscrewing (danger of injuries).





- Pull off cylindrical roller bearing toward front.





- Remove all parts from drive pinion and drive shaft, and mark needle bearings for installation.
- Loosen clamp nuts and remove drive pinion and drive shaft.
- Remove shims. Note number and thickness for installation.

Assembly

- Install shims in number and thickness as noted or as determined while adjusting the pinion.
- Install preassembled drive pinion and drive shaft.
^ Torque clamp nuts to: 22-25 Nm (16.2-18.4 ft lb)
- Install drive pinion and drive shaft as follows:
a. 4th speed gear II
b. Needle cage, spacer, 4th speed gear I
c. Operating sleeve for 3rd and 4th speed
d. Gearshift sleeve, selector fork and selector rod for 3rd and 4th speed
e. Bushing. spacer, needle cage, 3rd speed gear I
f. Spacer, 3rd speed gear II
g. Thrust washer, 2nd speed gear I
h. Bushing. needle cage, 2nd speed gear II
i. Operating sleeve for 1st and 2nd speed
j. Gearshift sleeve, selector fork and selector rod for 1st and 2nd speed
k. Bushing. spacer, needle cage. 1st speed gear II
l. Thrust washer
m. Spacer, 1st speed gear I
n. Cylindrical roller bearing

NOTE: Heat all press fit parts to about 120°C.

- Adjust selector forks. Adjustments -- 930 Transmission
- Install nut for drive pinion with a fluid adhesive (Loctite No. 73) and treat threads with Locquic Activator to assure a perfect lock.
^ Torque to: 190-200 Nm (140-147 ft lb)
- Torque drive shaft nut to: 160-180 Nm (118-133 ft lb)
- Lock nuts.