General Repair Instructions

REPAIR INSTRUCTIONS
General
Meticulous care and cleanliness and the correct servicing equipment are all necessary for achieving successful transmission repairs resulting in satisfactory performance. It is understood that all normal basic safety rules are applicable.

A number of universally valid instructions for individual repair procedures formerly repeated at various points within the repair instructions are summarized here. They are applicable to this repair information.

Transmission
When replacing transmission, refill with gear oil up to lower edge of filler hole

Refer to Specifications for fluid and capacity information

Ensure that the alignment sleeves fit properly between engine and transmission during installation

Gaskets And Seals
Replace paper gaskets

Thoroughly clean all joint surfaces before installation

Replace O-rings

Radial shaft seals

Before installation: Lubricate outer periphery of seal lightly and fill space between sealing lips with grease before installation.

After installation: Check transmission oil level; fill to lower edge of filler hole if necessary.

Retainers
Replace circlip

Do not over-stretch circlips

Circlips must seat fully in grooves





Replace spring pins
Installation position: Slot in direction of forces

Bearings
Install needle bearings with the side bearing inscription (thicker metal) toward the drift.

Coat all transmission bearings with gear oil before installing.

Lubricate especially thoroughly for bearing pre-load measurements.

Different taper roller bearings that are installed on the same shaft must always be replaced together. Use replacement bearings from the same manufacturer whenever possible.

Heat bearing inner races to approx. 100°C (212°F) before installing.

Bearings and races are matched sets. Do not interchange outer and inner races for bearings of the same size.

Adjustment Shims
Use a micrometer to measure shim thickness at several different points. Shim manufacturing tolerances make it possible to obtain the precise shim thickness required

Check for burrs and damage

Use only shims that are in perfect condition

Synchronizer Rings
Do not interchange. If synchronizer rings are to be reused, make sure that they are installed with their original gears.

Check for wear, replace where necessary.

Lubricate whit gear oil before installing.

Gears
Clean and heat to approx. 100°C (212°F) on a hot plate before pressing on.