Disassembling and Assembling the Drive Shaft
Disassembling and assembling the drive shaft
Preliminary work
1. Remove transmission.
2. Use engine support 9589 to secure the transmission on the assembly support.
3. Drain transmission oil.
4. Disassemble transmission.
Disassembling the drive shaft
Overview
1. Remove circlip -1-.
2. Remove deep-groove ball bearing -2- using material 00000 and separating device (25 - 155 mm [diameter]) NR.112-2 by applying pressure.
Deep-groove ball bearing
3. Take off loose gear wheel for 4th gear -3- with needle-roller bearing -4- and thrust washer -5-.
4. Remove circlip -6-.
Information
Careful disassembly of the synchronization unit while still assembled is recommended as this may prevent the loss of small parts.
5. Press off loose gear wheel for 3rd gear -17- with synchronization -7 to 16- using material 00000.
Loose gear wheel, 3rd gear
6. Take off thrust washer -18- and remove circlip -19-.
7. Press off loose gear wheel for 5th gear -26- with synchronization -23 to 35- and loose gear wheel for 6th gear -22- using material 00000. This also removes the bearing inner ring -20- and the bearing half shells -21-.
Loose gear wheel, 5th gear
8. Take bearing half shells -27- off the drive shaft -28-.
Assembling drive shaft
Information
When fitting new loose gear wheels, always check to see which needle-roller bearing should be used for the given radial play.
Information
When replacing a loose gear wheel, the related fixed gear wheel must also be replaced if the transmission mileage is more than 20,000 km.
Information
All transmission parts, particularly synchronization parts, must always be coated with transmission oil before assembly. Avoid assembling dry parts.
Overview
1. Check synchronization (5/6th gear) for wear. To do this, press the synchronizer ring -23- firmly onto the gear wheel by hand and measure the gap dimension with a feeler gauge.
Checking synchronization
Installation dimension (new): 1.6 to 0.8 mm
Wear dimension: 0.5 mm
2. Fit loose gear wheel for 5th gear -26- with needle-roller bearing half shells -27- on the drive shaft -28-.
3. Position synchronizer ring. Make sure the rectangular indentations on the synchronizer ring are positioned correctly with respect to the driver dogs.
Synchronization
4. Press guide sleeve -25- on using material 00000.
Guide sleeve
5. Fit synchronization -9 to 11 and 24-. The more deeply pulled radius -Arrow- must be facing the loose gear wheel for 5th gear.
Shift sleeve
6. Position synchronizer ring. Make sure the rectangular indentations on the synchronizer ring are positioned correctly with respect to the driver dogs.
Synchronization
7. Assemble loose gear wheel for 6th gear -22-, needle-roller bearing half shells -21- and bearing inner ring -20-.
8. Position the assembled components on the drive shaft, turn the drive shaft and insert it into the material 00000.
9. Press assembled components onto the drive shaft until there is a gap of around 1 cm remaining between the synchronizer ring and the shift sleeve.
Assembled components
10. Turn the drive shaft and press it on fully using material 00000.
Bearing inner ring
Information
Circlips of different sizes and thicknesses are used. New circlips must always be used when the old ones are removed. If a directly affected component is replaced, the largest circlip that can be used must be fitted.
11. Check which new circlip -19- you need to use and fit it.
Circlip
12. Fit thrust washer -18-.
13. Check synchronization (3rd gear) for wear. To do this, press the friction ring -15-, cone ring -14- and synchronizer ring -13- firmly onto the gear wheel by hand and measure the gap dimension with a feeler gauge.
Checking synchronization
Installation dimension (new): 1.5 to 0.9 mm
Wear dimension: 0.6 mm
14. Check synchronization (4th gear) for wear. To do this, press the synchronizer ring -7- firmly onto the gear wheel by hand and measure the gap dimension with a feeler gauge.
Checking synchronization
Installation dimension (new): 1.6 to 0.8 mm
Wear dimension: 0.5 mm
15. Fit loose gear wheel for 3rd gear -17- with needle-roller bearing -16- on the drive shaft.
16. Fit friction ring -15-, cone ring -14- and synchronizer ring -13- on the loose gear wheel for 3rd gear.
17. Press guide sleeve -12- on using material 00000. Make sure the rectangular indentations on the synchronizer ring are positioned correctly with respect to the guide sleeve.
Guide sleeve
18. Fit synchronization -8 to 11-. The more deeply pulled radius -Arrow- must be facing the loose gear wheel for 3rd gear.
Shift sleeve
19. Fit synchronizer ring -7-. Make sure the rectangular indentations on the synchronizer ring are positioned correctly with respect to the driver dogs.
Synchronization
Information
Circlips of different sizes and thicknesses are used. New circlips must always be used when the old ones are removed. If a directly affected component is replaced, the largest circlip that can be used must be fitted.
20. Check which new circlip -6- you need to use and fit it.
Circlip
21. Fit thrust washer -5-.
22. Fit loose gear wheel for 4th gear -3- with needle-roller bearing -4- on the drive shaft.
23. Press new bearing -2- on using material 00000.
Bearing
Information
Circlips of different sizes and thicknesses are used. New circlips must always be used when the old ones are removed. If a directly affected component is replaced, the largest circlip that can be used must be fitted.
24. Check which new circlip -1- you need to use and fit it.
Subsequent work
1. Assemble transmission.
2. Install transmission.
3. Fill with transmission oil.