Assembling Input Shaft
Assembling input shaftAssembling shafts
Note!
^ The overview diagram of the input shaft is provided in the chapter Disassembling transmission under.
1. Clamp shaft with special tool socket wrench insert 9282 in the vice.
2. Assemble synchronization if necessary. The synchronization consists of parts 19 to 14 and 11 in the overview. Pay attention to correct seating of the steel synchronizing rings -A- and the driver dogs -B-. The driver dogs with spring and ball must align with the dotting marks on the shift collar. Make sure also that the rectangular indentations of the synchronizing rings are positioned above the driver dogs.
3. Check the synchronizing rings for wear. To do this, push the synchronizing rings onto the gear wheels and measure the gap -A- with a feeler gauge.
Installation dimension (new): minimum 0.9 mm
Wear dimension: 0.6.....0.7 mm
Note!
^ Gear wheels may only be replaced in pairs. Always employ used needle-roller bearings with the same gear wheel and in the same running direction.
4. Push needle-roller bearing (no. 21 in overview), loose gear wheel for 3rd gear (no. 20 in overview) and synchronization onto input shaft.
5. Heat bearing inner race (no. 13 in overview) to 120°C and push onto input shaft.
6. Push loose gear wheel for 4th gear (nos. 12 and 10 in overview) and thrust plate (no. 9 in overview) onto input shaft. The large flat-ground side of the thrust plate faces towards the loose gear wheel for the 4th gear.
7. Heat bearing inner race (no. 6 in overview) to 120°C and push onto input shaft.
8. Fit clamping plate with short lock (nos. 5 and 8 in overview), four-point bearing (no. 4 in overview) and shift fork (no. 7 in overview) onto input shaft.
9. Heat bearing inner race (no. 3 in overview) to 120°C and push onto input shaft.
10. Heat cylindrical-roller bearing (no. 2 in overview) to 120°C and push onto input shaft.
11. Screw new hexagon nut onto input shaft.
Tightening torque: 250 Nm (185 ft. lbs.)
Tightening torques
Assembling input shaft
Assembling shaft
Note!
^ The overview diagram of the output shaft is provided in the chapter Disassembling transmission under.
1. Heat cylindrical-roller bearing (no. 6 in overview) to 120°C and push onto output shaft.
2. Heat bearing inner race (no. 5 in overview) to 120°C and push onto output shaft.
3. Push on four-point bearing (no. 4 in overview) onto output shaft.
4. Heat bearing inner race (no. 3 in overview) to 120°C and push onto output shaft.