Disassembling M47, M47 II

M47:

M47II:

1. Mount transmission on fixture P/N 5130 on floor stand P/N 2520 or bench support P/N 5154.





2. Drain oil.





3. Remove transmission cover and gasket. Remove selector plate.
4. Remove selector plate. Lift off washers, spring and interlocking ball.
5. Remove clutch fork. Save spacer washer. Remove release bearing.





6. Remove clutch housing ("bell housing") and gasket.
- Save adjusting shims.
- Tap pipe rearwards to loosen seal. Some pipes have a lock ring, remove it first.





7. Remove gear selector bracket and selector rod.





8. Remove drive flange.
- Engage two gears to lock transmission, prior to loosening nut.
- If drive flange is difficult to remove, use puller P/N 5304. It fits both the round and three-armed drive flanges.





9. Remove rear end cover and gasket.
10. Remove rear end cover seal.

NOTE: Transmission M 47 II proceed to operation 22.

Removing 5th gear, M 47
11. Remove bolt, washer and shims for counter-shaft. Reinstall bolt, 5-6 turns, no washer.





NOTE: Puller claws should be ground as shown.

12. Pull off 5th gear housing using puller P/N 998 7693-0.
- Remove gasket.
- Remove selector shaft seal.





13. Remove thrust washer and roller bearing with washer.





14. Pull off gear wheel from countershaft using universal puller.
15. Remove gear wheel with needle bearing, support ring and synchronizer ring from main shaft. Remove long bolt from countershaft.





16. Tap out three pins (1). Support shafts to prevent them from bending when pins are removed.
17. Pull out selector shafts (2).
18. Remove shift forks (3).





19. Remove spring and disassemble 5th gear synchronizer. Remove lock ring for hub.

5262 Puller:

20. Remove two upper screws retaining bearing holder.
21. Pull off hub using puller P/N 5262. Save adjusting shims.

NOTE: Operation 22-31 only apply to M47 II.

Removing 5th gear, M47 II
22. Remove bolt, washer and countershaft shims.

5973 Washer:

23. Pull off 5th gear housing.
- Refit bolt with washer P/N 5973. Tighten bolt by hand until it bottoms.
- Use puller P/N 998 7693 to pull off 5th gear housing.

NOTE: Grind puller claws as shown.

- Remove gasket and selector shaft seal.





24. Remove thrust washer and roller bearing with washer.





25. Tap out three pins (1). Support shafts to prevent them from bending when pins are removed.
26. Pull out selector shafts (2).
27. Remove shift forks (3).

5305 Ring:

28. Pull off 5th gear wheel. Remove two upper bearing holder screws using puller P/N 5262 and ring P/N 5305.





29. Pull off 5th gear wheel and synchronizer using universal puller, supported on bolt head.





30. Disassemble 5th gear wheel/synchronizer.
- Clamp a box-end wrench in a vice. Place synchronizer nut in wrench.
- Use shaft P/N 5986 plus torque wrench to loosen nut.

CAUTION: If nut comes loose at a lower torque than 30 Nm (22 ft lb), a new nut should be used when reassembling.

- Dismantle parts.





31. Remove retainer on 5th gear synchronizer hub. This operation should only be performed if a part is to be replaced. Use screwdriver to pry retainer loose.

5261 Puller:

32. Pull out front countershaft bearing using puller P/N 5261. Insert puller claws between rollers, pull out spindle to expand puller and pull out bearing.





33. Remove bearing holder from rear face. Save adjusting shims.





34. Remove rear main shaft bearing.
- Position support P/N 2985 between input shaft and front synchronizer ring. Remove lock ring and bearing.
- Use puller P/N 5058 (without spindle), extension P/N 5148 and puller bolt P/N 5147.

NOTE: Extension tool P/N 5148 has been modified in production. The modification consists of increasing the tool hole inside diameter from 29 mm (1.14 inch) to 3O-30.5 mm (1.18-1.20 inch).

Removing All Shafts





35. Remove input shaft with synchronizer ring. Pull out shaft. If bearing is hard to remove leave support P/N 2985 in position and tap main shaft with a mallet.

NOTE: Make sure that front part of countershaft abuts bottom of housing.





36. Remove main shaft. Turn transmission and remove main shaft.
37. Remove countershaft.
- Turn transmission back.
- Tap out rear bearing race with a plastic mallet.
- Remove countershaft.





38. Remove reverse gear and shaft using a drift to force shaft rearwards.
39. Remove reverse gear shift fork

Disassembling Main Shaft





40. Transmission with damper: Press off washer. Remove springs and brake ring.





41. Remove thrust washer and 1st gear wheel with synchronizer ring. Remove lock rings for synchronizer hubs.





42. Press off 1st-2nd synchronizer hub and 2nd gear wheel with synchronizer ring using support P/N 2853.
43. Press off 3rd-4th synchronizer hub and 3rd gear wheel using support P/N 2853.





44. Disassemble both synchronizers.





45. Remove bearing on countershaft using puller P/N 5131.





46. Remove input shaft bearing using support P/N 2853.





47. Remove bearing races from 5th gear housing using brass drift.
48. Clean and check:
- Clean all parts in solvent. Dry with compressed air.
- Check all parts. Replace all worn or damaged parts and all gaskets and seals.