Assembling Front Gear Set
Assembling front gear setNote!
^ The overview diagram of the front gear set is provided in the chapter Disassembling transmission under.
Assembling gear set
1. Place thrust plate (no. 30 in overview) onto output shaft.
2. Heat bearing inner race (no. 29 in overview) to 120°C and place on output shaft.
3. Place fixed gear wheel for 6th gear (no. 37 in overview) onto the input shaft. The large collar faces the spacer sleeve (no. 36 in overview).
4. Place spacer sleeve (no. 36 in overview) onto input shaft.
5. Check the synchronizing rings for wear. To do this, push the synchronizing rings onto the gear wheels and measure the gap -A- with a feeler gauge.
Installation dimension (new): minimum 0.9 mm
Wear dimension: 0.6.....0.7 mm
6. Place loose gear wheel for 6th gear (no. 27 in overview) with needle-roller bearing (no. 28 in overview) onto output shaft.
7. Assemble synchronization (nos. 26, 24 to 20 and 17 in overview). The rectangular recesses of the synchronizing ring must be positioned above the driver dogs in the case of the steel synchronizing ring (no. 26 in overview).
Note!
^ The dotting marks on the shift collar must be centered with respect to the recesses in the guide sleeve.
8. Place synchronization with shift fork (no. 25 in overview) onto output shaft.
9. Heat bearing inner race (no. 19 in overview) to 120°C and place on output shaft.
10. Place loose gear wheel for 5th gear (no. 16 in overview) with needle-roller bearing (no. 18 in overview) onto output shaft.
11. Place fixed gear wheel for 5th gear (no. 35 in overview) onto the input shaft. The large collar faces the spacer sleeve (no. 36 in overview).
12. Place spacer sleeve (no. 34 in overview) onto input shaft.
13. Assemble synchronization (nos. 15 to 12 and 8 in overview).
Note!
^ The dotting marks on the shift collar must be centered with respect to the recesses in the guide sleeve.
14. Check the synchronizing ring for wear. To do this, press synchronizing ring onto the tapered end of the gear wheel and measure gap -A- with a feeler gauge.
Installation dimension (new): minimum 0.9 mm
Wear dimension: 0.6.....0.7 mm
15. Place synchronization with shift fork (no. 8 in overview) onto output shaft.
16. Heat bearing inner race (no. 7 in overview) to 120°C and place on output shaft.
17. Place loose gear wheel for reverse gear (no. 4 in overview) with needle-roller bearing (no. 6 in overview) and synchronizing ring (no. 5 in overview) onto output shaft.
18. Place fixed gear wheel for reverse gear (no. 33 in overview) onto input shaft.
19. Heat bearing inner race (no. 32 in overview) to 120°C and place on input shaft.
20. Tighten new self-locking nuts (no. 31 in overview) on input shaft.
Tightening torque: 200 Nm (148 ft. lbs.)
21. Place thrust plate (no. 3 in overview) onto output shaft.
22. Heat cylindrical-roller bearing (no. 2 in overview) to 120°C and place on output shaft.
23. Tighten new self-locking nuts (no. 1 in overview) on output shaft.
Tightening torque: 300 Nm (222 ft. lbs.)
24. Adjust shift forks (nos. 25 and 11 in overview). The shift collar must have slight play in both directions in idle position.
25. Secure shift forks with screws and washers (nos. 9 and 10 in overview).
Tightening torque: 18 Nm (13 ft. lbs.)
26. Remove special tool retaining device 9253.
27. Shift through all gears as a test.
Tightening torques