Disassembling and Assembling the Output Shaft

Disassembling and assembling the output shaft








Preliminary work

1. Remove transmission.
2. Use engine support 9589 to secure the transmission on the assembly support.
3. Drain transmission oil.
4. Disassemble transmission.

Disassembling output shaft





Overview








1. Remove circlip -1-.
2. Press off inner bearing ring -2- with fixed gear wheel for 4th gear -3- using material 00000.





Fixed gear wheel, 4th gear

3. Remove spacer sleeve -4-.
4. Press off fixed gear wheel for 3rd gear -5- using material 00000.





Fixed gear wheel, 3rd gear

5. Press off fixed gear wheel for 6th gear -6- using material 00000.





Fixed gear wheel, 6th gear

6. Remove spacer sleeve -4-.
7. Press the shift sleeve -15- in the direction of the loose gear wheel for 1st gear -21-, thereby switching to 1st gear.
8. Press off fixed gear wheel for 5th gear -7- and loose gear wheel for 2nd gear -8- using material 00000.





Loose gear wheel, 2nd gear

9. Remove needle-roller bearing -9- and thrust washer -10-.
10. Remove circlip -11-.

Information
Careful disassembly of the synchronization unit while still assembled is recommended as this may prevent the loss of small parts.

11. Press off loose gear wheel for 1st gear -21- with entire synchronization unit -12 to 19- using material 00000.





Loose gear wheel, 1st gear

12. Remove needle-roller bearing -20- and thrust washer -22-.
13. Remove circlip -23-.
14. Press off fixed gear wheel for reverse gear -24- with tensioning plate -25- using material 00000.





Reverse gear wheel

15. Loosen caulking between output shaft -30- and nut -26-.





Caulking

Information
Output shaft and nut are connected by a left thread. The direction of rotation must be observed when loosening and tightening.

16. Remove nut from output shaft using material 00000.





Nut

17. Press off complete main bearing -27 to 29- using material 00000.





Pressing off bearing

Assembling output shaft

Information
When fitting new loose gear wheels, always check to see which needle-roller bearing should be used for the given radial play.

Information
When replacing a loose gear wheel, the related fixed gear wheel must also be replaced if the transmission mileage is more than 20,000 km.

Information
All transmission parts, particularly synchronization parts, must always be coated with transmission oil before assembly. Avoid assembling dry parts.





Overview








1. Heat up new taper roller bearing -29- to approx. 150°C and fit it on the output shaft -30-.
2. Fit new outer bearing ring -28-.
3. Heat up new taper roller bearing -27- to approx. 150°C and fit it.

Information
Output shaft and nut are connected by a left thread. The direction of rotation must be observed when loosening and tightening.

4. Fit new nut -26- using material 00000.





Nut





5. Fit tensioning plate -25-.
6. Press on fixed gear wheel for reverse gear -24- using material 00000. The large collar on the fixed gear wheel must be pointing towards the loose gear wheel for 1st gear.





Pressing on fixed gear wheel for reverse gear

Information
Circlips of different sizes and thicknesses are used. New circlips must always be used when the old ones are removed. If a directly affected component is replaced, the largest circlip that can be used must be fitted.

7. Determine which circlip must be used and fit new circlip -23-.





Circlip

8. Fit thrust washer -22-.
9. Check synchronization (1st/2nd gear) for wear. To do this, press the friction ring -12-, cone ring -13- and synchronizer ring -14- firmly onto the gear wheel by hand and measure the gap dimension with a feeler gauge.





Checking synchronization

Installation dimension (new): 1.5 to 0.9 mm

Wear dimension: 0.6 mm

10. Fit loose gear wheel for 1st gear -21- with needle-roller bearing -20-.
11. Fit friction ring -12-, cone ring -13- and synchronizer ring -14-.
12. Press on guide sleeve -16- using material 00000. The large collar on the guide sleeve must be pointing towards the loose gear wheel for 2nd gear.





Pressing on guide sleeve

13. Fit synchronization -19 to 15-. The wider side -Arrow- must be pointing towards the loose gear wheel for 1st gear.





Shift sleeve

Information
Circlips of different sizes and thicknesses are used. New circlips must always be used when the old ones are removed. If a directly affected component is replaced, the largest circlip that can be used must be fitted.

14. Determine which circlip must be used and fit new circlip -11-.





Circlip

15. Fit thrust washer -10-.
16. Fit friction ring -12-, cone ring -13- and synchronizer ring -14-.
17. Fit loose gear wheel for 2nd gear -8- with needle-roller bearing -9-.
18. Press on fixed gear wheel for 5th gear -7- using material 00000. The large collar on the fixed gear wheel must be pointing towards the fixed gear wheel for 6th gear.





Pressing on fixed gear wheel for 5th gear

19. Spacer sleeve -4-
20. Press on fixed gear wheel for 6th gear -6- using material 00000. The large collar on the fixed gear wheel must be pointing towards the fixed gear wheel for 3rd gear.





Fixed gear wheel, 6th gear

21. Press on fixed gear wheel for 3rd gear -5- using material 00000. The large collar on the fixed gear wheel must be pointing towards the fixed gear wheel for 4th gear.





Fixed gear wheel, 3rd gear

22. Spacer sleeve -4-
23. Press on fixed gear wheel for 4th gear -3- using material 00000. The large collar on the fixed gear wheel must be pointing towards the inner bearing ring.





Fixed gear wheel, 4th gear

24. Heat up the inner bearing ring -2- to approx. 150°C and fit it.

Information
Circlips of different sizes and thicknesses are used. New circlips must always be used when the old ones are removed. If a directly affected component is replaced, the largest circlip that can be used must be fitted.

25. Determine which circlip must be used and fit new circlip -1-.





Circlip

Subsequent work

1. Assemble transmission.
2. Install transmission.
3. Fill with transmission oil.