Upper Main Shaft, Dismantling and Assembly
Upper main shaft, dismantling and assemblyTo remove
1. Remove the gearbox. See Gearbox assembly.
2. Remove the gearcase. See Gearcase, seal.
3. Remove the drive shaft, lower main shaft and gear lever shaft 1st/2nd - 5th/6th.
4. Remove the upper main shaft with gear lever shaft 3rd/4th/reverse gear.
5. Remove 4th and the conical roller bearing inner ring. Press off with DT-46756 (87 93 036 Support, to remove, lower main shaft) and DT-46754 (87 93 028 Drift, removal of main shafts). Remove 4th and the conical roller bearing inner ring and needle bearing.
6. Remove the shift sleeve to 3rd/4th. Remove the shift sleeve, baulk rings and the thrust collars.
7. Remove the circlip on synchromesh assembly 3rd/4th. Use KM-396 or 87 90 180 Pliers.
8. Remove 3rd and synchromesh assembly 3rd/4th. Press off 3rd with DT-46754 (87 93 028 Drift, removal of main shafts ). Remove 3rd with needle bearing, baulk rings and synchromesh assembly.
9. Remove the spacer ring. Press off with DT-46773 ( 87 93 069 Support, to remove, upper main shaft) and DT-46754 (87 93 028 Drift, removal of main shafts) .
10. Remove the shift sleeve, reverse gear. Remove the shift sleeve and thrust collars.
11. Remove the circlip to synchromesh assembly, reverse gear. Use KM-396 or 87 90 180 Pliers.
12. Remove the reverse gear and synchromesh assembly, reverse gear. Press off the reverse gear with DT-46754 (87 93 028 Drift, removal of main shafts). Remove the synchromesh assembly with baulk rings, reverse gear, needle bearing and spacer ring.
To fit
1. Fit the reverse gear and synchromesh assembly, reverse gear. Fit the spacer washer and the needle bearing on the upper main shaft. It is important to check that the gears are fitted correctly. Fit the baulk rings and synchromesh assembly on the reverse gear.
2. Hold together the synchromesh assembly and the reverse gear and at the same time press on the upper main shaft with DT-46759 or 87 91204 Sleeve, bearing race.
3. Fit the circlip for the synchromesh assembly, reverse gear. It is important that the circlip is fully engaged. Fit a new circlip with KM-396 or 87 90 180 Pliers .
Note: Make sure that the fitting position for the groove on the shift sleeve, reverse gear, (arrow) is pointed towards the reverse gear.
4. Fit the shift sleeve, reverse gear. Fit in the thrust collars and the shift sleeve.
5. Fit the spacer ring. Press on with DT-46759 or 87 91 204 Sleeve, bearing race.Make sure that the step points towards the reverse gear.
6. Fit 3rd and synchromesh assembly 3rd/4th. Fit the needle bearing on the main shaft. Carefully check that the gears are fitted correctly. Fit the synchromesh assembly and the baulk rings on 3rd.
7. Hold together the synchromesh assembly and 3rd and at the same time press on the upper main shaft with DT-46759 or 87 91 204 Sleeve, bearing race.
8. Fit the circlip for synchromesh assembly 3rd/4th. It is important that the circlip is fully engaged. Fit a new circlip with KM-396 or 87 90 180 Pliers .
9. Fit the shift sleeve for 3rd/4th. Fit the shift sleeve on the synchromesh assembly. Fit in the thrust collars.
10. Fit 4th. Fit the needle bearing on the main shaft. Fit the baulk rings in the synchromesh assembly. Carefully check that the gears are fitted correctly. Fit 4th on the synchromesh assembly 3rd/4th.
11. Fit the conical roller bearing inner ring in the gearcase side. Press on with KM 6120 or 87 91261 Puller, pinion on the main shaft.
12. Fit the upper main shaft with gear lever shaft, 3rd/4th/reverse gear.
13. Fit the drive shaft, the lower main shaft and gear lever shaft, 1st/2nd - 5th/6th. Fit in the shafts together.
14. Fit Gearcase, seal.
15. Fit Gearbox assembly.