Disassembling and Assembling the Input Shaft

Tools











Disassembling and assembling the input shaft (transmission G 86)

Disassembly

Note Since snap rings of different sizes and thicknesses are used, the individual snap rings must be identified (e.g. with numbers). The thickness of the individual snap ring must be determined again if a directly affected component is replaced.





1. Press off the 5th gear fixed gear wheel using a suitable separating device (e.g. Kukko 17/2, 22... 115 mm).
2. Press off the synchronizing elements for the 3rd and 4th gears using a suitable separating device (e.g. Kukko 17/2, 22-115 mm).





Note Before fitting the separating device, press the synchronizing ring for the 3rd gear (arrow) to the loose gear wheel for the 3rd gear.

Assembly





1. Check the synchronizing rings for wear. To do this, press the ring into the shift sleeve and measure the gap dimension "a" with a feeler gauge in positions A, B and C. Add up the measured values and divide by 1 The value obtained must not be below 0.5 mm.





2. Insert the spring into the loose gear wheel so that the angled end engages in the hole.





3. Install the selector sleeve so that the slant (arrow 1) faces the 4th gear and the offset side (arrow 2) faces the 3rd gear.





4. Determine the snap ring for the 4th gear. To do this, determine the thickest ring which can still just be used.

Note Determine the snap ring for the 5th gear in exactly the same way.





5. Heat the synchronizing elements for the 3rd and 4th gears to approximately 100 T and press on (high collar facing the 3rd gear loose gear wheel).





6. Heat the fixed gear wheel for the 5th gear to approximately 100° C and press on (high collar to the reverse gear and the oil pockets to the 4th gear).