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Home >> Mercedes Benz >> 2002 >> SLK230 Automatic >> Repair and Diagnosis >> Transmission >> Manual Trans >> Gear Assembly, Shafts, Differential - SLK230 & SLK320 - 716.622/630/660/662/667 >> Overhaul >> Disassembling And Assembling Main Shaft With Input Shaft >> Assembling Main Shaft

Assembling Main Shaft

NOTE: Diesel and gasoline-engine vehicles are fitted with different gear wheels (with the exception of the gear wheels for 1st gear and reverse gear).

In order to distinguish between these gear wheels, those for diesel vehicles (with the exception of the gear wheels for 1st gear and reverse gear) have a groove (arrow) in the teeth. See Figure.

NOTE: When pressing on new synchronizer bodies, swarf may be produced and this must be removed.
NOTE: Clean main shaft with compressed air.
  1. 1 -  Clamp main shaft (27) in vise with protective jaws.
    NOTE: Input end uppermost.
    2. Fig 1: Assembling Main Shaft (1 Of 19)
    G00389303Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  2. 2 -  Install 6th gear needle bearing (28).
  3. 3 -  -Install idler gear for 6th gear (29).
    NOTE: The straight teeth must point upwards (towards the input end). See Fig 1.
  4. 4 -  Install clutch body (30).
    NOTE: The outer teeth must point downwards (towards the output end).
    5. Fig 2: Assembling Main Shaft (2 Of 19)
    G00389304Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. 5 -  Install synchronizer ring (31).
    NOTE: The teeth must point downwards (towards the output end).
    NOTE: New synchronizer units are supplied already assembled.

    Only if necessary:

  6. 6 -  Assemble new synchronizer unit:
  7. 6.1 -  Push sliding sleeve (36) onto 5th/6th gear synchronizer body (32).
    NOTE: When pushing on the sliding sleeve (36), align it to ensure that the balls (35) will subsequently engage in the center groove of the sliding sleeve teeth (arrow).
    Fig 3: Assembling Main Shaft (3 Of 19)
    G00389305Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. 6.2 -  Install narrow sliders (34), compression springs (33) and balls (35) in 5th/6th gear synchronizer body (32).
    NOTE: The widths of the sliders used for the individual synchronizer bodies vary:

    Slider widths:

    • 1st/2nd gear synchronizer body - Wide sliders (15 mm).
    • 3rd/4th gear synchronizer body - Wide sliders (15 mm).
    • 5th/6th gear synchronizer body - Narrow sliders (9 mm).
    • Reverse gear synchronizer body - Narrow sliders (9 mm).

  9. 7 -  Press on new 5th/6th gear synchronizer unit (52) using sleeve.
    NOTE: The inscription on the synchronizer body must face upwards (towards the input end). The drivers on the synchronizer ring (31) must engage in the grooves in the synchronizer body.
    Fig 4: Assembling Main Shaft (4 Of 19)
    G00389306Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  10. 8 -  Determine thickness of locking ring (39):
    • Insert trial ring (thickness: 1.5 mm) using pliers and press all the way down (towards the output end).
    • Measure distance between trial ring and top edge of groove in main shaft (27) using feeler gauge.
    • Thickness of locking ring = measured value + 1.5 mm (trial ring).
    • Remove trial ring using pliers.

    Use Pliers. See Figure.

    11. Fig 5: Assembling Main Shaft (5 Of 19)
    G00389307Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  11. 9 -  Use pliers to install new locking ring (39) of the determined thickness (increments: 0.05 mm).
    NOTE: Do not over-expand the locking ring. Ensure that the locking ring is properly seated.
  12. 10 -  Install synchronizer ring (37)
    NOTE: The drivers on the synchronizer ring (37) must engage in the grooves in the 5th/6th gear synchronizer body.
    13. Fig 6: Assembling Main Shaft (6 Of 19)
    G00389308Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  13. 11 -  I nstall clutch body (38). The outer teeth must point upwards (towards the input end).
    NOTE: The outer teeth must point upwards (towards the input end).
  14. 12 -  Oil cylindrical roller bearing (40) and place in input shaft (41).
    15. Fig 7: Assembling Main Shaft (7 Of 19)
    G00389309Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  15. 13 -  Place input shaft (41) on main shaft.
  16. 14 -  Remove main shaft with input shaft (41) from vise, turn over and clamp input shaft (41) in vise with protective jaws.
  17. 15 -  Install 2nd gear needle bearing (26).
    Fig 8: Assembling Main Shaft (8 Of 19)
    G00389310Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  18. 16 -  -Install idler gear for 2nd gear (25).
    NOTE: The collar must point upwards (towards the output end).
  19. 17 -  Install friction ring (24).
    NOTE: The lobes must point upwards (towards the output end).
    20. Fig 9: Assembling Main Shaft (9 Of 19)
    G00389311Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  20. 18 -  Install cone ring (23).
    NOTE: The lobes on the cone ring (23) must engage in the recesses in the idler gear for 2nd gear.
  21. 19 -  Install synchronizer ring (22).
    NOTE: The teeth must point downwards (towards the input end).

    The lobes on the friction ring (24) must engage in the recesses in the synchronizer ring (22).

    NOTE: New synchronizer units are supplied already assembled.

    Only if necessary:

  22. 20 -  Assemble new synchronizer unit:
  23. 20.1 -  Push sliding sleeve (17) onto 1st/2nd gear synchronizer body (18).
    NOTE: When pushing on the sliding sleeve (17), align it to ensure that the balls (21) will subsequently engage in the center groove of the sliding sleeve teeth (arrow).
    24. Fig 10: Assembling Main Shaft (10 Of 19)
    G00389312Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  24. 20.2 -  Install wide sliders (20), compression springs (19) and balls (21) in 1st/2nd gear synchronizer body (18).
  25. 21 -  Install new 1st/2nd gear synchronizer unit (51) and press on using sleeve.

    Use appropriate Sleeve. See Figure or Figure .

    CAUTION: The orientation groove (arrow at bottom) on the sliding sleeve must point downwards (towards the input end). If the sliding sleeve is installed rotated in the wrong direction, the transmission can jump out of 2nd gear.
    NOTE: The lobes (arrow at top) on the synchronizer ring must engage in the recesses in the 1st/2nd gear synchronizer body.
    26. Fig 11: Assembling Main Shaft (11 Of 19)
    G00389313Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  26. 22 -  Determine thickness of locking ring (16):
    • Insert trial ring (thickness: 1.5 mm) using pliers and press all the way down (towards the input end).
    • Measure distance between trial ring and top edge of groove in main shaft using feeler gauge.
    • Thickness of locking ring = measured distance + 1.5 mm (trial locking ring).

      Remove trial ring using pliers.

    27. Fig 12: Assembling Main Shaft (12 Of 19)
    G00389314Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  27. 23 -  Use pliers to install new locking ring (16) of the determined thickness (increments: 0.05 mm).
    NOTE: Do not over-expand the locking ring. Ensure that the locking ring is properly seated.
  28. 24 -  Install synchronizer ring (15).
    NOTE: The teeth must point upwards (towards the output end).
    29. Fig 13: Assembling Main Shaft (13 Of 19)
    G00389315Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  29. 25 -  Install cone ring (14).
    NOTE: The lobes must point upwards (towards the output end).
  30. 26 -  Install friction ring (13).
    NOTE: The lobes on the friction ring (13) must engage in the recesses in the synchronizer ring (15).
  31. 27 -  Install 1st gear needle bearing (12).
    32. Fig 14: Assembling Main Shaft (14 Of 19)
    G00389316Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  32. 28 -  Install idler gear for 1st gear (11).
    NOTE: The cone must point downwards (towards the input end). The lobes on the synchronizer ring must engage in the recesses in the idler gear for 1st gear (11).
  33. 29 -  Install thrust washer (10) and press on using sleeve.

    Use appropriate Sleeve. See Figure or Figure .

  34. 30 -  Press on sleeve (9) using drift.

    Use Drift (711 589 07 15 00). See Figure.

    35. Fig 15: Assembling Main Shaft (15 Of 19)
    G00389317Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  35. 31 -  Install reverse gear needle bearing (8).
  36. 32 -  Install idler gear for reverse gear (7).
    NOTE: The collar must point upwards (towards the output end).
    37. Fig 16: Assembling Main Shaft (16 Of 19)
    G00389318Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  37. 33 -  Install synchronizer ring (6).
    NOTE: The teeth must point downwards (towards the input end).
    NOTE: New synchronizer units are supplied already assembled.

    Only if necessary:

  38. 34 -  Assemble new synchronizer unit.
  39. 34.1 -  Push sliding sleeve (1) onto reverse gear synchronizer body (2).
    NOTE: The closed side of the grooves in the reverse gear synchronizer body (2) must face downwards.
    Fig 17: Assembling Main Shaft (17 Of 19)
    G00389319Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Push on the sliding sleeve (1) with the tapered sides of the tooth flanks pointing upwards, so that the balls (5) will subsequently engage in the center groove in the sliding sleeve teeth (arrow).

    Fig 18: Assembling Main Shaft (18 Of 19)
    G00389320Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  40. 34.2 -  Install narrow sliders (4), compression springs (3) and balls (5) in reverse gear synchronizer body (2).
  41. 35 -  Install new reverse gear synchronizer assembly (50) and press on using sleeve.
    NOTE: The recesses in the synchronizer ring must engage in the grooves in the reverse gear synchronizer body.
    42. Fig 19: Assembling Main Shaft (19 Of 19)
    G00389321Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  42. 36 -  Remove input shaft together with main shaft from vise.
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