Output Shaft: Service and Repair

IMPORTANT INFORMATION!

Modified operating sleeves, synchromesh rings and gear wheels since 5.85 Check installed position of operating sleeves and synchromesh rings.
Operating sleeves with asymmetric teeth.
Operating sleeve (1) without groove installed with stepped end facing 1st gear.
Operating sleeve (3) with 2 grooves installed with stepped end facing 3rd gear.
Operating sleeve (5) with 1 groove installed with stepped end facing reverse gear.

IDENTIFICATION OF SYNCHROMESH:

Always check the tooth width in order to avoid mixing up synchromesh rings.
Synchromesh ring (1) for 1st/reverse gear: narrow teeth.
Synchromesh ring (2) for 2nd, 3rd, 4th and 5th gears: wide teeth.

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 input shaft (1), brass synchromesh ring (2) and needle bearing (3).

- Pull off thrust washer (4), 5th gear (5), brass synchromesh ring (6) and needle bearing (7).

- Lift out circlip (8).
- Remove spacer (9).

Installation Note:
Adjust play between circlip and guide sleeve to 0.0 - 0.09 mm (0 to 0.0035 in).
Always replace circlip.

- Press second gear, bearing sleeve, third gear, synchromesh ring and guide sleeve with operating sleeve off of output shaft with Special Tool 23 2 080.
Pressing-off force: 3.0 tons maximum

Version with Thrust Washer:
- Note thrust washer (2) and ball (3) between 2nd and 3rd gear wheels.

NOTE:
Snap ring (10) must be removed before pressing off 1st gear.
Always replace circlip.

- Press off 1st gear with guide sleeve and sliding sleeve with Special Tool 23 1 490.
Pressing-off force: 3.7 tons maximum
- Remove needle bearing.

NOTE:
Circlip (11) must be removed before pressing off reverse gear.
Always replace circlip.

- Press off guide sleeve with operating sleeve and reverse gear with Special Tool 23 2 080 that the bottom faces the gear wheel.
Pressing-off force: 3.7 tons maximum
- Remove needle bearing.

ASSEMBLY:

- Install needle bearing, reverse gear and brass synchromesh ring with molybdenum coat.
- Place guide sleeve and sliding sleeve on splines of output shaft.

NOTE: Since 5.85: Stepped end of operating sleeve must face the reverse gear.

- Press on guide sleeve to fit tight with Special Tool 23 1 290.
Pressing-on force: 2.5 tons maximum

NOTE: When pressing on parts, make sure that tabs on synchromesh ring are aligned with openings in guide sleeve.

- 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.
- Place guide sleeve and operating sleeve on splines of output shaft.

NOTE: Since 5.85: Stepped end of operating sleeve must face the first gear wheel.

- Adjust guide sleeve 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 (10).

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

NOTE:
Collar for bearing sleeve on output shaft must protrude slightly.
If applicable, check circlip (10) for correct fit.

- Heat bearing sleeve to approx. 80°C (175°F) with a hot air blower and install on output shaft.

Version with Thrust Washer:
- Install ball (3) and thrust washer (2) with opening facing ball (3).

- Heat bearing sleeve (4) without collar to approx. 80°C (175°F) with a hot air blower and install on output shaft.

- Install needle bearing, 3rd gear and brass synchromesh ring.
- Place guide sleeve and operating sleeve on splines with long collar facing 3rd gear.

NOTE: Since 5.85: Stepped end of operating sleeve must face the 3rd gear wheel.

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

NOTE:
When pressing on parts, make sure that tabs on synchromesh ring are aligned with openings in guide sleeve.
Install spacer and circlip.

- Install needle bearing (3), brass synchromesh ring (2) and input shaft (1).

- Install needle bearing (7), brass synchromesh ring (6), 5th gear (5) and thrust washer (4).