Output Shaft: Service and Repair

DISASSEMBLING:

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 5th gear (4), brass synchromesh ring (5) and needle bearing (6) from the back end of the output shaft.

- Pull off input shaft (1), brass synchromesh ring (2) and needle bearing (3) from the front end of the output shaft.

- Lift out circlip (7).
- Remove spacer (8).

Installation Note:

- Adjust play between circlip and guide sleeve to 0 .. 0.09 mm (0 to 0.0035 in).
- Always replace circlip.

NOTE:
- Operate 3rd/4th gear operating sleeve by hand in direction of 3rd gear.

- Press off 3rd gear with guide and operating sleeves, using Special Tool 23 1 490.
Pressing-off force: 2.7 tons maximum
- Remove needle bearing.

- Press off bearing sleeve and 2nd gear with Special Tool 23 1 490.
Pressing-off force: 3.0 tons maximum
- Remove nickel-plated synchromesh ring and needle bearing.

NOTE:

- Remove circlip (10) before Pressing-off 1st gear.

Installation Note:
- Always replace circlip.

- Press off 1st gear with guide and operating sleeve, using Special Tool 23 1 490.
Pressing-off force: 3.0 tons maximum
- Remove needle bearing.

NOTE:

- Remove circlip (11) before Pressing-off reverse gear.

Installation Note:
Always replace circlip.

- Support output shaft next to collar.

- Press guide and operating sleeves as well as reverse gear off of output shaft.
Pressing-off force: 3.0 tons maximum
- Remove needle bearing.

ASSEMBLING:

- Install needle bearing, reverse gear, brass synchromesh ring with molybdenum coat (only for version with synchronized reverse gear).
- Install guide and operating sleeves on splines of output shaft.

CAUTION:

- Version Without Reverse Gear Synchronization: Circlip (1) in guide sleeve must face reverse gear.

- Press on guide sleeve to fit tight with Special Tool 23 1 290.
Pressing-on force: 2.1 tons maximum

CAUTION: Make sure tabs on synchromesh ring are aligned with openings in guide sleeve while Pressing-on.

- Move operating sleeve in direction of reverse gear.

- Adjust guide sleeve with circlip (11) to take up all play.
- Circlips are available from Parts in different thicknesses from 1.7 to 2.0 mm (0.067 to 0.079 in).
- Install circlip (11).

- Install needle bearing, 1st gear and nickel-plated synchromesh ring.
- Install guide and operating sleeves on splines of output shaft.

NOTE: Operating Sleeves with Different Teeth: Stepped end of operating sleeve must face second gear.

- Move operating sleeve in direction of 1st gear.
- Adjust guide sleeve to remove all play.
- Circlips are available from Parts in different thickness from 1.7 to 2.0 mm (0.067 to 0.079 in).
- Install circlip (10).

- Install needle bearing, nickel-plated synchromesh ring and 2nd gear.

CAUTION:
- Collar for bearing sleeve on output shaft must protrude slightly.
- If necessary, check circlip (1) for proper fit.

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

- Install needle bearing, 3rd gear and nickel-plated synchromesh ring.
- Install guide and operating sleeve on spline with groove facing 4th gear.

- Press on guide sleeve to fit tight with Special Tool 23 1 290.
Pressing-on force: 1.9 tons maximum

CAUTION: Make sure tabs on synchromesh ring are aligned with openings in guide sleeve while Pressing-on.

- Install spacer and circlip.

- Install input shaft (1), brass synchromesh ring (2) and needle bearing (3) on the front end of the output shaft.

- Install 5th gear (4), brass synchromesh ring (5) and needle bearing (6) on the back end of the output shaft.