Replacing Output Shaft

Replacing Output Shaft
- Output shaft Removed -

NOTE:
It is recommended to mark synchromesh rings and their corresponding gear wheels when disassembling the output shaft, in order to avoid mixing up synchromesh rings.
Care must be taken with the needle bearing for each gear so as not to mix them up or dislodge the bearings from their cage.





- Pull off input shaft (1), synchromesh ring (2) made of brass and needle bearing (3).





- Lift out circlip (4).

Installation Note:





Always replace circlip.
Adjust guide sleeve with circlip (4) to take up all play.
Circlips are available from Parts in different thicknesses.





- Press 3rd gear with guide and sliding sleeves off of output shaft with Special Tool 23 1 490.
- Remove needle bearing.





- Press bearing sleeve, thrust washer and 2nd gear off of output shalt with Special Tool 23 1 490.
- Remove needle bearing and sintered steel synchromesh ring.





NOTE:
Circlip (5) must be removed before pressing off 1st gear.
Always replace circlip.





- Press 1st gear with guide and sliding sleeves off of output shaft with Special Tool 23 1 490.
- Remove needle bearing.





- Press thrust washer and 5th gear off of output shaft with Special Tool 23 1 490.
- Remove brass synchromesh ring and needle bearing.





NOTE:
Circlip (6) must be removed before pressing off reverse gear.
Always replace circlip.





- Install output shaft next to collar.





- Press guide sleeve with sliding sleeve and reverse gear off of output shaft.
- Remove needle bearing.
- Remove brass synchromesh ring with 6 balls, only for version with reverse gear synchronization.


ASSEMBLING:





- Install needle bearing,reverse gear and brass synchromesh ring with 6 balls (only for version with reverse gear synchronization), use grease to hold balls in place.
- Install guide and sliding sleeve with narrow collar facing reverse gear.





- Press on guide sleeve to fit tight with Special Tool 23 1 290.

NOTE: Make sure that short tabs of synchromesh ring are aligned with groove in pressure pieces when pressing on guide sleeve.

- Move sliding sleeve in reverse gear direction.





- Adjust guide sleeve with circlip (6) to take up all play.
- Circlips are available from Parts in different thicknesses.
- Always install a new circlip (6).





- Install brass synchromesh ring with short tabs of synchromesh ring in groove of pressure pieces.
- Install needle bearing and 5th gear.





- Heat thrust washer (7) to approx. 80°C (175°F) and install on output shaft.





- Install needle bearing, 1st gear and sintered steel synchromesh ring.
- Install guide sleeve and sliding sleeve with narrow collar facing 1st gear.





- Press on guide sleeve to fit tight with Special Tool 23 1 290.

NOTE: When pressing on make sure that short tabs of synchromesh ring are aligned with groove in thrust pieces.

- Move sliding sleeve in 1st gear direction.





- Adjust guide sleeve to be without play.
- Circlips are available from Parts in different thicknesses.
- Always install a new circlip (5).





- Install sintered steel synchromesh ring with short tabs of synchromesh ring in groove of pressure pieces.
- Install needle bearing and 2nd gear.





NOTE:
Output shaft collar for thrust washer must protrude slightly.
If necessary, check circlip (5) for correct fit.

- Heat thrust washer (8) to approx. 80°C (175°F) and install on output shaft.





- Heat bearing sleeve (9) to approx. 80°C (175°F) and install on output shaft.





- Install needle bearing, 3rd gear and brass synchromesh ring.
- Install guide sleeve and sliding sleeve with long collar facing 3rd gear wheel.

NOTE:
- Version with Identification Groove:
Groove faces the 3rd gear wheel.





- Press on guide sleeve to fit tight with Special Tool 23 1 290.

NOTE:
- When pressing on make sure that short tabs of synchromesh ring are aligned with groove in thrust while pressure pieces.

Install circlip.





Adjust axial play of input shaft.
Output shaft and case front setion installed.
Input shaft must rest on Synchromesh ring.
Measure distance (A) from guide sleeve sealing
Surface to input shaft.

- Measure distance (A) from guide sleeve sealing surface to input shaft.





- Measure distance (B) from guide sleeve sealing surface to circlip bearing surface.

NOTE:If spacer had been found between the circlip and case while removing the bearing it must be installed again for measuring.





- Measure distance (C) from bearing outer race to circlip.

NOTE: Circlip must be pressed tight in groove for measuring.

EXAMPLE:
A 25.5 mm (1.003 in)
- B 10.3 mm (0.405 in)
--------------------------------
15.2 mm (0.598 in)
- C 14.0 mm (0.551 in)
--------------------------------
1.2 mm (0.047 in)

Axial play required: 1.1 to 1.3 mm (0.043 to 0.051 in).
Circlips are available from Parts in different thicknesses for making corrections.

- Install grooved ball bearing