Assembling M47, M47 II

Assembling main shaft
1. Assemble both synchronizers. Place hub in operating sleeve. 3rd-4th gear synchronizer: Three recesses in hub should align with three bevelled teeth in operating sleeve.





2. Install sliding keys (1) and springs (2).
- Lock sliding keys ("dogs") with springs. Hook both springs to the same sliding key.
- Install one spring counter-clockwise. Turn synchronizer over and install second spring, also counter-clockwise.
- If spring is bent, free end must point away from hub.





3. Oil main shaft. Install 3rd gear wheel and synchronizer ring. Press on 3rd-4th gear synchronizer hub.
- Make sure synchronizer ring is facing correct way.
- Turn wear surface on synchronizer hub UP. Use support P/N 2852.





Invert Shaft
4. Oil shaft. Install 2nd gear wheel and synchronizer ring. Press on 1st-2nd gear synchronizer hub. Make sure synchronizer ring is fitted correctly. Use support P/N 2852.
5. Install lock rings for both synchronizers





Transmission Without Damper (step 6):
6. Install synchronizer ring and gear wheel for 1st gear and thrust washer.





Transmission With Damper (steps 8-9):
7. Install thrust washer (1) if applicable, synchronizer ring (2) and 1st gear wheel (3).

8. Assemble damper. Oil parts. Position springs in brake ring and twist washer into brake ring.

9. Press damper (4) on main shaft. Use a file to remove sharp edges. Use P/N 5090 to press on damper.





10. Press rear bearing on countershaft. Use drift P/N 2413.





11. Press bearing on input shaft. Use standard handle P/N 1801 and support P/N 2853.
12. Install lock ring on input shaft.

Installing Shafts

NOTE: Apply assembly paste to aluminium surfaces prior to installing bearings and shafts. P/N 1161 006-9 Aerosol, P/N 1161 078-9 Can.





13. Position reverse gear shift fork. Install lock ring.
14. Install reverse gear and shaft.





15. Check/adjust position of reverse gear. Shaft end should be flush with housing or max. 0.05 mm (0.002 in) below housing face.
16. Check/adjust clearance between reverse gear wheel and shift fork. Adjust by tapping shift fork bearing stud, with a drift. Correct clearance: 0.1-1.0 mm (0.004-0.040 in).

NOTE: M 47: proceed to operation 22. Operations 17 to 21 only apply to M 47 II.





Assembling 5th gear Synchronizer and Gear Wheel
17. Fit retainer to 5th gear synchronizer hub. Use drift P/N 2413. First position spring counter-clockwise in hub.

NOTE: When installing the retainer, ensure raised portion of retainer is flush with the inner raised portion of the hub. If the retainer is pressed too far onto the hub the synchronizer dogs (tangs) will cause the synchronizer ring to drag against the gear after assembly. This will make it difficult to correctly shim the countershaft.

18. Assemble hub and operating sleeve. Three recesses in hub should align with three bevelled teeth in operating sleeve. Hub washer and bevelled part of operating sleeve should face same direction.





19. Install sliding keys (1) and spring (2). The two springs should hook on to the same sliding key. Position spring counter-clockwise as shown in illustration.





20. Assemble shaft, needle bearing, gear wheel and synchronizer. Bevelled edge of sleeve should face gear wheel. Install nut finger tight.





21. Torque nut. Clamp a 42 mm box-end wrench in a vice. Place nut in box-end wrench. Use shaft P/N 5986 and torque wrench. Torque to 120 Nm (88 ft lb).

NOTE:
^ During tightening, torque should be 40-80 Nm (30-60 ft lb). If below, replace nut.

^ After tightening the attaching nut to the correct torque specification, ensure that the 5th gear spins freely on the shaft. Use a new nut to retain the assembly. This will eliminate the need to check the torque during the tightening process.





22. Place countershaft in bottom of housing.
23. Place main shaft in housing. First turn housing.





Installing Rear Bearing On Main Shaft
24. Position bearing with lock ring on main shaft. Countershaft should lie in bearing recesses.

5306 Press Tool:

25. Press main shaft bearing into position. Use press tool P/N 5306.

CAUTION: Take care not to damage gear teeth when pressing bearing into position.

26. Make sure bearing lock ring abuts housing. If necessary, tap press tool with a mallet until bearing seats correctly.





27. Install rear countershaft bearing race using drift tool P/N 2413.

NOTE: Top of race must be above. Race will take correct position when cage is installed.





Determining Thickness Of Main Shaft Shims
Main shaft end float should be 0.01-0.20 mm (0.0004-0.0080 in). If main shaft bearing or bearing holder has been replaced, shim thickness should be determined.

28. Measure distance between outer face of main shaft bearing and rear face of transmission housing. Use depth micrometer and note reading.





29. Measure distance between bearing holder contact face and bearing seat bottom. Note reading.








30. Calculate thickness of shims for main shaft.





31. Install bearing holder. Torque to 15-25 Nm (11-20 ft lb). Tap bearing holder to seat bearing races.

NOTE: Do not interchange short bolts with long cover bolts.





32. Transmissions with damper: Check torque for output shaft. Use torque gauge P/N 9177 and hold 1st gear wheel by hand. Correct torque: 0.8-2.5 Nm (7-22 in lb).

NOTE: M 47 II: Proceed to operation 37. Operations 33 to 36 only refer to M 47.

Installing 5th Gear Synchronizer Hub
33. Calculating shim thickness. Adjust bearing position to obtain a clearance of max 0.20 mm (0.008 in) to lock ring.





34. Install original shim, as applicable.
35. Install lock ring.





36. Measure clearance between lock ring and hub. If clearance exceeds 0.20 mm (0.008 in), remove hut and install shim.





Example

NOTE: Proceed to operation 38. Operation 37 only applies to M 47 II.





Installing 5th Gear Wheel
37. Press on spacer washer, 5th gear wheel and bearing race. Use press tool P/N 5306 with thrust washer as support.

Installing Input Shaft
38. Position 4th gear synchronizer ring in synchronizer hub.





39. Grease and install roller bearing in input shaft.





40. Install input shaft, lift countershaft.
- Tap bearing with a plastic mallet if it is difficult to move it.
- Lift intermediate shaft before positioning input shaft.

2413 Drift:

41. Install front countershaft bearing. Use drift P/N 2413.

NOTE: M 47 II proceed to operation 45. Operations 42 to 44 only refer to M 47.





Assembling 5th Gear Synchronizer, M 47
42. Install 3 sliding keys.
43. Position sleeve so that bevelled teeth align with sliding keys.
44. Install spring.

NOTE: Proceed to operation 47. Operations 45 to 46 only refer to M 47 II.





Installing 5th Gear And Synchronizer, M 47 II

45. Install 5th gear synchronizer and gear wheel on countershaft. First pull out operating sleeve so that half of hub becomes visible. Then install synchronizer and gear wheel on countershaft.





46. Press on synchronizer and gear wheel. Install bolt and washer. Tighten until bolt bottoms.





47. Install 1st-2nd and 3rd-4th gear selector fork, gear selector and selector shaft. Make sure sliding lugs are positioned correctly. Gear selector lug should face forwards.





48. Install 5th gear shift fork, gear selector and selector shaft. Gear selector lug should face forwards.





49. Install locking pins (3 x).
- Grooves in selector shaft should face UP.
- Pin in 5th gear shift fork should be flush with surface. Support 5th gear selector shaft when tapping pins into position.

NOTE: M 47 II: Proceed to operation 53. Operations 50 to 52 only refer to M 47.

Installing 5th Gear Wheel, M 47





50. Grease and install two needle bearings (1) and spacer (2) in 5th gear wheel.
51. Install synchronizer ring on synchronizer hub





52. Install both gear wheels.
- Install bolt and washer on countershaft.
- Pull bolt to press on large gear wheel.
- Make sure large gear wheel is correctly positioned.
- Remove bolt and washer.





53. Install washer, roller bearing and thrust washer. Enclosed side of bearing should face rearwards.





54. Install bearing races and selector shaft seal in 5th gear housing.
- Tap bearing races into position with a plastic mallet.
- Use a socket to install selector shaft seal.





55. Grease contact face, position gasket and install 5th gear housing. Carefully tap 5th gear housing into position.

Determining Countershaft Shim Thickness
Countershaft should have an end float of 0.01-0.10 mm (0.0004-0.0040 in). If countershaft, any of its bearings, or the rear case/intermediate housing have been replaced the shim thickness must be determined.





56. Install rear countershaft bearing M 47 II: Using support tool P/N 2985, press bearing halfway onto fifth gear shaft. If the bearing is driven too far onto the shaft, it will be impossible to correctly shim the countershaft. Install correct washer with a 0.55 mm shim, P/N 3204069-3, then tighten bearing into correct position.

NOTE: Make sure washer teeth align with gear teeth.

5096 Spacer:

57. Attach 5th gear housing. Use shift bracket bolts and 4 x P/N 5096 (B28-tools) as spacers.
58. Install Support 2985 on one of the bolts. Torque bolts to 35-50 Nm (26-37 ft lb).





59. Position dial indicator. Push up and turn shaft to set front bearing. Calibrate dial indicator zero.
60. Lower and turn shaft to set rear bearing. Read dial indicator. Note reading.








61. Calculate thickness of countershaft shim.





62. Install new shim pack, washer and a new self-locking bolt, or use thread locking compound P/N 1161053-2. Engage two gears to lock transmission. Torque to 35-45 Nm (25-32 lb lb).





Installing Rear End Cover
63. Make sure vent hole is not blocked.
64. Install seal in rear end cover. Grease and install output shaft seal. Use drift P/N 5064. Seal should be positioned 2,5 mm (0.1 in) inside flange.





65. Grease housing face and position gasket.
66. Use two bolts to attach rear end cover.
67. Attach gear selector rod. Grease and install rubber ring in joint. Use sleeve to lock pins.





68. Install selector bracket. Torque bolts to 35-50 Nm (25-35 ft lb).

NOTE: Bolt - washer - spacer tube - washer.






69. Install drive flange. Engage two gears to lock transmission. Torque nut to:
- Bolt M16 70-90 Nm (50-60 ft lb)
- Bolt M2O 90-110 Nm (65-80 ft lb)





70. Grease and install seal in bell housing.
- Make sure pipe is at bottom.
- Use drift P/N 2867 and standard handle 1801.

Determining Input Shaft Shim Thickness
Permitted end float: 0.01-0.20 mm. (0.0004-0.0080 in). If input shaft, bearing on input shaft, or clutch housing has been replaced, shim thickness must be determined.





71. Position gasket on clutch housing.
72. Measure distance between gasket top and bearing seat bottom. Note distance.





73. Make sure bearing spacer washer abuts housing.
74. Measure distance between upper face of input shaft bearing and front face of transmission housing. Use depth micrometer and note reading.








75. Calculate input shaft shim thickness.





76. Grease transmission gasket face and position gasket.
77. Position shim in clutch housing. Apply grease to hold shim in position.





78. Install bell housing. Torque to 35-50 Nm (25-35 ft lb).
79. Install clutch release fork, washer and release bearing.
- First apply grease to bearing sliding surface and ball joint.
- Sparingly apply grease to splines.
- Do not forget to place washer beneath ball.





80. Install sliding washers and selector plate.





81. Check function. Move selector plate by hand to check that all gears can be engaged and disengaged.
82. Install interlock ball and spring.
83. Grease housing face and position gasket





84. Install transmission cover. Torque bolts to 15-25 Nm (11-20 ft lb)