Disassemble Main Shaft

Tools called out for in this procedure. See Figure, Figure and Figure .

1. 1 -  Using protective jaws, clamp the input shaft (41) in a vice.
Fig 1: Disassembling Main Shaft (1 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. 2 -  Place the main shaft (27) on the input shaft (41).
3. 3 -  Use puller (53) and jaw (54) to remove 1st gear idler gear (11). See Fig 1.
4. 4 -  Remove reverse gear synchronizer assembly (50).
Fig 2: Disassembling Main Shaft (2 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. 5 -  Remove synchronizer ring (6) and reverse gear idler gear (7).
Fig 3: Disassembling Main Shaft (3 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. 6 -  Remove reverse gear needle roller bearing (8) with sleeve (9).
Fig 4: Disassembling Main Shaft (4 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. 7 -  Remove thrust plate (10), 1st gear idler gear (11) and 1st gear needle roller bearing (12).
Fig 5: Disassembling Main Shaft (5 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. 8 -  Remove friction ring (13), cone ring (14) and synchronizer ring (15).
Fig 6: Disassembling Main Shaft (6 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. 9 -  Remove circlip (16) with pliers.
Fig 7: Disassembling Main Shaft (7 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
10. 10 -  Use puller to pull off 1st/2nd gear synchronizer assembly (51).
11. 11 -  Remove synchronizer ring (22), cone ring (23) and friction ring (24).
Fig 8: Disassembling Main Shaft (8 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
12. 12 -  Remove 2nd gear idler gear (25) and 2nd gear needle roller bearing (26).
Fig 9: Disassembling Main Shaft (9 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
13. 13 -  Remove main shaft (27) from the input shaft (41).
Fig 10: Disassembling Main Shaft (10 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. 14 -  Remove synchronizer ring (37) and clutch body (38).
15. 15 -  Remove cylindrical roller bearing (40) from the input shaft (41).
16. 16 -  Release the input shaft (41) from the vice. See Fig 10.
17. 17 -  Turn the main shaft around and clamp it in the vice using protective jaws.
    NOTE: Input end uppermost.
Fig 11: Disassembling Main Shaft (11 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
18. 18 -  Use the pliers to remove the circlip (39).
19. 19 -  Remove the synchronizer cone and clutch body (arrows) with the puller prior to removing the 5th/6th gear synchronizer assembly (52). See Fig 11.
20. 20 -  Remove the synchronizer ring (31) and clutch body (30).
Fig 12: Disassembling Main Shaft (12 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
21. 21 -  Remove 6th gear idler gear (29) and needle roller bearing (28). See Fig 12.
22. 22 -  Release the input shaft (27) from the vise.
Fig 13: Disassembling Main Shaft (13 Of 13)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.