Assembling Transmission

343537 Assembling Transmission

Tools








Information:
- If the transmission to be opened is still in the guarantee period (3 Years), the letter -R- must be imprinted after the transmission number.
- Use the Damage Catalogue to diagnose in the transmission.


Assembling Input Shaft

Assembling Shafts

Note:
^ The overview diagram of the input shaft is provided in the chapter disassembling transmission under Disassembling input shaft.

1. Clamp shaft with special tool socket wrench insert 9282 in the vice.





2. Assemble synchronization if necessary. The synchronization consists of parts 19 to 14 and 11 in the overview. Pay attention to correct seating of the steel synchronizing rings -A- and the driver dogs -B-. The driver dogs with spring and ball must align with the dotting marks on the shift collar. Make sure furthermore that the rectangular indentations of the synchronizing rings are positioned above the driver dogs.





3. Check the synchronizing rings for wear. check synchronizing rings by pushing them onto the gear wheels and measuring the gap -A- with a feeler gauge.
Installation dimension (new): min. 0.9 mm
Wear dimension: 0.6 - 0.7 mm

Information:
- Gear wheels may only be replaced in pairs. Always employ used needle-roller bearings with the same gear wheel and in the same running direction.

4. Push needle-roller bearing (no. 21 in overview), 3rd gear loose gearwheel (no. 20 in overview) and synchronization onto input shaft.

5. Heat bearing inner race (no. 13 in overview) to 120°C and push onto input shaft.

6. Push 4th gear loose gearwheel (no. 12 and 10 in overview) and thrust plate (no. 9 in overview) onto input shaft.

7. Heat bearing inner race (no. 6 in overview) to 120°C and push onto input shaft.

8. Fit clamping plate with short lock (no. 5 and 8 in overview), four-point bearing (no. 4 in overview) and shift fork (no. 7 in overview) onto input shaft.

9. Heat bearing inner race (no. 3 in overview) to 120°C and push onto input shaft.

10. Heat cylindrical-roller bearing (no. 2 in overview) to 120°C and push onto input shaft.

11. Screw new hexagon nut onto input shaft.
Tightening torque: 250 Nm (185 ft. lbs.)


Tightening torques






Installing input and output shaft

Installing shafts

Note:
^ An overview diagram of the installation is provided in the chapter 'disassembling transmission' under Removing input and output shaft.





1. Insert output shaft -A- with adjusting shim S5 -Band adjusting shim S4 -C- into tensioning plate -F-.

2. Push 4th gear fixed wheel -D- onto output shaft. The large collar faces the tensioning plate.

3. Push on the spacer sleeve -E-.





4. Affix adjusting shim S3 -A- in the transmission case with viscous grease.

5. Insert input and output shaft into the transmission case with tensioning plate and tighten nuts.
Tightening torque: 25 Nm (18.5 ft. lbs.)

6. Push on 3rd gear fixed gear (no. 21 in overview) onto the output shaft. The large collar faces the thrust plate.

7. Push thrust plate onto the output shaft.

8. Heat bearing inner race (no. 19 in overview) to 120°C and push onto output shaft.

9. Push needle-roller bearing (no. 18 in overview) onto bearing inner race.





10. Check synchronization of 2nd gear. To do this, place the friction ring (no. 16 in overview), the tapered ring (no. 15 in overview) and the synchronisation ring (no. 14 in overview) on the gear wheel (no. 17 in overview). Measure the gap -A- with a feeler gauge. Perform test again in the same way for 1st gear.
Installation dimension (new): 1.5 to 2.0 mm
Wear dimension: 1.2 mm

11. Push 2nd gear loose gearwheel (no. 17 in overview) onto needle-roller bearing.

12. Insert friction ring (no. 16 in overview), tapered ring (no. 15 in overview) and synchronization ring (no. 14 in overview) into the guide sleeve (no. 10 in overview) and push onto output drive. In doing so, the recess of the inner toothing of the guide sleeve must align with the oil bore of the output shaft.

13. Heat bearing inner race (no. 8 in overview) to 120°C and push onto output shaft.





14. Fit shift collar (no. 9 in overview) with shift rod for 1st/2nd gear (no. 23 in overview). The turned groove -A- in the shift collar must face the 2nd gear loose wheel.

Note:
^ The dotting marks on the shift collar must be centered with respect to the recesses in the guide sleeve.





15. When setting the shift collar in place, ensure that the dotting marks on the shift collar are centered with respect to the recesses in the guide sleeve.
1 Shift collar
2 Ball
3 Driver dog
4 Spring
A Recognition groove
B Dotting mark
C 2nd gear - side
D 1st gear - side

16. Fit spring (no. 11 in overview), ball (no 12 in overview) and driver dog (no. 13 in overview). To do this, push the shift collar in the direction of the 2nd gear loose gearwheel.

17. Fit the synchronizing ring (no. 6 in overview), the tapered ring (no. 5 in overview) and friction ring (no. 4 in overview).

18. Push needle-roller bearing (no. 7 in overview) onto bearing inner race.

19. Push 1st gear loose gearwheel (no. 3 in overview) and thrust plate (no. 2 in overview) onto output shaft.

20. Heat cylindrical-roller bearing (no. 1 in overview) to 120°C and push onto output shaft.

21. Heat cylindrical-roller bearing (no. 31 in overview) to 120°C and push onto input shaft.






22. Fit shift rods, selector shaft and locking elements. Affix locking elements with viscous grease if necessary. Ensure that the rollers on the selector shaft are complete.
1 Shift rod for 3rd/4th gear
2 Locking element (short)
3 Shift rod for 5th/6th gear
4 Intermediate lock
5 Locking element (long)
6 Reverse gear shift rod
7 Intermediate lock
8 Locking element (short)
9 Shift rod for 1st/2nd gear

23. Fit locking elements (no. 32, 33 and 34 in overview).
Tightening Torque: 15 Nm (11 ft lbs).

Note:
^ Do not move the shift rods past the neutral lock or gear lock during or after fitting as otherwise the small locking elements and the balls of the lock can fall into the transmission.

Tightening torques





Fitting Gear Housing

Fitting housing
1. Coat gear housing with Loctite 574 and put it on. To do this, insert shift rods into suitable bearing locations and ensure correct engaging of the shift catch roller in the driver of the selector shaft.
2. Screw in fastening screws.
Tightening torque: 23 Nm (17 ft. lbs.)
3. Fit locking pin, spring and plug screw.
Tightening torque: 25 Nm (19 ft. lbs.)

Tightening torques





Assembling Front Gear Set

Note:
^ The overview diagram of the front gear set is provided in the chapter 'disassembling transmission' under Disassembling front gear set.

Assembling gear set

1. Place thrust plate (no. 31 in overview) onto output shaft.

2. Heat bearing inner race (no. 30 in overview) to 120°C and place on output shaft.

3. Place fixed gear for 6th gear (no. 38 in overview) onto the
input shaft.The large collar faces the spacer sleeve (no. 37 in overview).
4. Place spacer sleeve (no. 37 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): min. 0.9 mm
Wear dimension: 0.6 - 0.7 mm

6. Place loose gearwheel for 6th gear (no. 28 in overview) with needle-roller bearing (no. 29 in overview) onto output shaft.





7. Assemble synchronization (no. 27, 25 to 21 and 18 in overview). The rectangular recesses of the synchronization ring must be positioned above the driver dogs in the case of the steel synchronization 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. 26 in overview) onto output shaft.

9. Heat bearing inner race (no. 20 in overview) to 120°C and place on output shaft.

10. Place loose gearwheel for 5th gear (no. 17 in overview) with needle-roller bearing (no. 18 in overview) onto output shaft.

11. Place fixed gear for 5th gear (no. 36 in overview) onto the input shaft.

12. Place spacer sleeve (no. 35 in overview) onto input shaft.

13. Assemble synchronization (no. 16, 13 to 9 and 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 gear wheels and measure the gap -A- with a feeler gauge.
Installation dimension (new): min. 0.9 mm
Wear dimension: 0.6 0.7 mm

15. Place synchronization with shift fork (no. 12 in overview) onto output shaft.

16. Heat bearing inner race (no. 8 in overview) to 120°C and place on output shaft.

17. Place loose gearwheel for reverse gear (no. 5 in overview) with needle-roller bearing (no. 7 in overview) and synchronization ring (no. 6 in overview) onto output shaft.

18. Place fixed gearwheel for reverse gear (no. 34 in overview) onto input shaft.

19. Heat bearing inner race (no. 33 in overview) to 120°C and place on input shaft.

20. Tighten new self-locking nuts (no. 32 in overview) on input shaft.
Tightening torque: 200 Nm (148 ft. lbs.)

21. Place thrust plate (no. 4 in overview) onto output shaft.

22. Heat cylindrical-roller bearing (no. 3 in overview) to 120°C and place on output shaft.

23. Tighten new self-locking nuts (no. 2 in overview) on output shaft.
Tightening torque: 300 Nm (222 ft. lbs.)

24. Adjust shift forks (no. 26 and 12 in overview). The shift collar must have slight play in both directions in idle position.

25. Secure shift forks with screws and washers (no. 10 and 11 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





Fitting Front Transmission Case Cover

Fitting cover

1. Coat front transmission case cover with Loctite 574, put on and screw in fastening screws.
Tightening torque: 23 Nm (17 ft. lbs.)

2. Imprint the letter -R- after the transmission number (only on transmission in guarantee period).

3. Fill with transmission oil.

Tightening torques