Disassembly/Assembly of Transmission

Disassembly

Transmission Assembly:

Legend 1:

Legend 2:

Legend 3:

Legend 4:

Legend 5:

- Refer to images for instructions and legends.

NOTE: To facilitate assembly, the gearwheel set is not removed completely but the drive pinion is partially dismantled before removal.





- Lock input shaft with special tool 9253 and engage 5th gear.





- Unscrew collar nuts of input and output shafts.





- Pull off inner bearing race of input shaft cylindrical roller bearing.





- Use a suitable puller to remove sleeve of reverse gear needle bearing. If necessary, rework the claws of the puller or push the 5th gear wheel forward a few millimeters with two tire levers.













- Use a suitable claw puller to disassemble drive pinion.

Assembly





- Place the number "S3" of shims of the correct thickness as noted during disassembly or calculated during adjustment of the drive pinion over the stud bolts of the case.









1 = Selector Rod 3/4
1 = Lock
3 = Selector Rod 5/R
4 = Locking Dowel
5 = Lock
6 = Selector Rod 1/2

- Lightly grease small locking dowel and insert in selector rod 5/R and mount rod in clamping plate.





- Install preassembled gear set with internal selector arm. Tighten clamping plate securing nuts with 23 Nm (16 ft lb).
- Assemble drive pinion.





- Install selector fork/selector rod with dowels in place together with complete guide sleeve.





- Use an approximately 50 mm long stud (improvised tool, 16 mm dia.) to guide the spring-loaded detent sleeve to its installation position.

NOTE: With differential installed, a 0.20 0.25 mm feeler gauge can also be used to mount the selector rod.





- Install complete guide sleeve with selector fork (if fork does not move freely on selector rod, use a cold chisel to expand clamp slightly).





- Tighten collar nut on drive pinion and output shaft to specified torque setting and lock by punching collar.





- Adjust selector fork for 5th and reverse gears. Set selector sleeve above the 5/R fork so that in the neutral position, the sleeve is located exactly in the middle between synchronizing rings.