Input Shaft Removal

Input Shaft Removal/Installation (Part 1 Of 5):

Input Shaft Removal/Installation (Part 2 Of 5):

Input Shaft Removal/Installation (Part 3 Of 5):

Input Shaft Removal/Installation (Part 4 Of 5):

Input Shaft Removal/Installation (Part 5 Of 5):

Removal Notes

NOTE: Parts No. 1 to 30 are removed with the tensioning plate remaining fitted.

Installation Notes
1. Using a suitable flat iron bar, clamp tensioning plate in a vise in such a manner that the hole for the shift rod locks is horizontal.
2. Check synchromesh of 1st and 2nd gears.
- To do so, place friction ring, tapered ring and synchronizing ring in correct position onto gearwheel.
- Check gap "A" with a feeler gauge.
Old design installation dimension:
New: 1.3 to 1.95 mm
Wear dimension: 1.0 mm
New design, installation dimension:
New: 1.5 to 2.0 mm
Wear dimension: 1.2 mm (see below)
3. Observe installation position of locks.

NOTE:
- After fitting the shift rods, do not move them across the neutral or gear latch positions as this may cause the small intermediate locks to drop out inadvertently.
- To avoid inadvertent movement of the shift rods, lock shift rods by engaging 4th gear.


Modified Synchromesh On 1st And 2nd Gear
- The following parts have been modified from transmission No.:
G 5020 1 000 884
G 5020 2 000 883
G 5021 1 002 186
G 5021 2 001 230
- Shift Sleeve (with three plunge-milled grooves on the inside teeth).
- Friction Ring (changed dimensions and marking 94)
- The following part has been modified from transmission No.:
G 5020 1 000960
G 5020 2 000927
G 5021 1 002238
G 5021 2 001294
- Compression Spring (unloaded length 16.22 mm)

New Component Identification
Shift Sleeve





Friction Ring





NOTE:
- Old and new parts must not be installed together in the same transmission. As only the modified parts are now available, all the modified parts must be installed in the event of repair work.
- The following points must be noted:
Install the shift sleeve on the guide sleeve with the punch marks "B" centered between the balls.
New installation and wear dimensions
New Installation: 1.5 to 2.0 mm
Wear Dimension: 1.2 mm





- Continuous groove "A" must point towards 2nd gear.