Disassembling Front Gear Set
Disassembling front gear setOverview
No. Designation Qty
1 Hexagon nut (self-locking) 1
2 Cylindrical-roller bearing 1
3 Thrust plate 1
4 Loose gear wheel, reverse gear 1
5 Synchronising ring 1
6 Needle-roller bearing 1
7 Bearing inner race 1
8 Shift collar 1
9 Washer 2
10 Hexagon-head bolt 2
11 Shift fork (reverse gear) 1
12 Spring 3
13 Ball 3
14 Driver dog 3
15 Guide sleeve with snap ring 1
16 Loose gear wheel, 5th gear 1
17 Synchronising ring 1
18 Needle-roller bearing 1
19 Bearing inner race 1
20 Shift collar 1
21 Driver dog 3
22 Ball 3
23 Spring 3
24 Guide sleeve 1
25 Shift fork (5th and 6th gears) 1
26 Synchronising ring 1
27 Loose gear wheel, 6th gear 1
28 Needle-roller bearing 1
29 Bearing inner race 1
30 Thrust plate 1
31 Hexagon nut (self-locking) 1
32 Bearing inner race 1
33 Fixed gear wheel, reverse gear 1
34 Spacer sleeve 1
35 Fixed gear wheel, 5th gear 1
36 Spacer sleeve 1
37 Fixed gear wheel, 6th gear 1
38 Housing 1
Disassembling gear set
Note!
^ All needle-roller bearings which are not replaced must be designated in terms of the installation position and allocation to the gear wheel.
1. Remove front transmission case cover.
2. Fix the transmission with special tool retaining device 9253 and shift into gear.
3. Remove nut -A- on input and output shaft.
4. Unscrew clamping screw from shift forks -B-.
5. Remove fixed gear wheel for reverse gear (no. 33 in overview) from the input shaft using the puller and special tool pressure pieces 9656. When doing so, pull off bearing inner race (no. 32 in overview).
6. Remove spacer sleeve (no. 34 in overview) from the input shaft.
7. Remove loose gear wheel for reverse gear (no. 4 in overview) with needle-roller bearing (no. 6 in overview) from the output shaft using the puller and special tool pressure pieces 9656. When doing so, also pull off the cylindrical-roller bearing (no. 2 in overview) and thrust plates (no. 3 in overview).
8. Push complete gear set forwards 1 - 2 cm onto output shaft using two mounting levers.
9. Push gear set back behind the bearing inner race (no. 7 in overview) and remove bearing inner race using the puller and special tool pressure pieces 9656.
10. Open up shift fork and remove complete synchronization.
11. Remove fixed gear wheel, 5th gear (no. 35 in overview) and the spacer sleeve (no. 34 in overview).
12. Remove loose gear wheel for 5th gear (no. 16 in overview) with needle-roller bearing (no. 18 in overview).
13. Remove bearing inner race (no. 19 in overview) using puller and special tool pressure pieces 9656.
14. Open up shift fork and remove complete synchronization.
15. Remove loose gear wheel for 6th gear (no. 27 in overview) with needle-roller bearing (no. 28 in overview).
16. Remove bearing inner race (no. 29 in overview) using puller and special tool pressure pieces 9656.
17. Remove thrust plate (no. 30 in overview).