Replacement

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.





Disassembly
1. Place the shaft in a screw vice with protective jaw faces.




2. Remove locking ring.




3. Press out the bearing from the shaft.
- Use puller ring tool No. 87 92 152 and basic tool No. 87 91 642, or equivalents.

NOTE: A removed bearing may not be reused (it is damaged).




4. Lift out the 4th gear's pinion, synchromesh and needle bearing.




5. Lift up the sleeve slightly and use your hand to catch the spring-loaded rolls so that they do not fly out.
- Place the rolls in a safe place.
6. Lift out the sleeve.

NOTE:
- Note how the sleeve is placed.
- If it is to be reinstalled, it should be installed turned the same way.




7. Place all springs and plungers in a safe place.




8. Remove the locking ring that holds the synchromesh hub.
- Remove the hub.




9. Lift out the 3rd gear's synchromesh, gearing and needle bearing.
10. Check the condition of all parts as regards wear.
- Replace damaged or defective parts.
- Measure the wear on the synchromesh by installing it in its place.
- Measure with a feeler gauge in three places between the baulk ring and the pinion and calculate a mean value.
- New synchromesh 0.8-1.1 mm
- Minimum measurement 0.5 mm.
- If less than minimum: replace synchromesh.

Assembly

NOTE: Oil all parts with suitable 10W30 engine oil before installing.

1. Install input shaft in a screw vice with protective jaw faces.




2. Insert the 3rd gear's pinion with its needle bearing and baulk ring.




3. Insert the synchromesh hub, ensure that the hub goes down over the baulk ring.
- If necessary, press with bearing race tool No. 87 92 202, or equivalent.
4. Install a new locking ring.
- Install the locking ring with the sharper edge facing upwards.




5. Check the axial play between the 2nd and 3rd gears' pinions.
- The play should be 0.05-0.40 mm




6. Install springs and plungers.




7. Insert the sleeve.

NOTE: The high heels of the sleeve should install into the deep teeth of the hub.




8. Install the rolls.
- The rolls are installed by pressing in the springs.
- You can use a feeler gauge to press in the springs.




9. Install the 4th gear's baulk ring, needle bearing and pinion.




10. Make sure that the pinion is turned the right way, press on a new bearing next to the 4th gear's pinion.
- Use sleeve tool No. 87 91 261, or equivalent.
- Install a new locking ring with the bevelled edge facing upwards.

CAUTION:

- Open the locking ring carefully before installing just enough to be able to install it on the shaft.
- If the locking ring is opened too much, it will be damaged.
- Carefully tap the locking ring into the grove of the shaft with a drift.




11. To check that the input shaft is correctly installed, check the play between the bearing and the 4th gear's pinion.
- The play should be 0.05-0.40 mm