Assembly Instructions For Output Shaft

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Information

All transmission parts, particularly synchronization parts, must always be coated with transmission oil before assembly. Avoid assembling dry parts.

Check triple-cone synchronization (1st gear) for wear. To do this, press the friction ring, cone ring and synchronizer ring onto the gear wheel and measure the gap dimension with a feeler gauge.

Fig 1: Identifying Gap Between Friction Ring, Cone Ring, Synchronizer Ring And Gear Wheel Gap
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Installation dimension (new): 1.4 to 2.0 mm

Wear dimension: 0.6 mm
Check double-cone synchronization (2nd gear) for wear. To do this, press the friction ring and synchronizer ring firmly onto the gear wheel by hand and measure the gap dimension with a feeler gauge.

Fig 2: Identifying Gap Between Friction Ring, Synchronizer Ring And Gear Wheel Gap
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Installation dimension (new): 1.4 to 2.0 mm

Wear dimension: 0.6 mm
Check single-cone synchronization for wear.
- Push ring into shift sleeve.
- Measure gap dimension -a- with a feeler gauge in positions -A, B and C- .
- Add up the measured values and divide by three. The value obtained must not be less than 0.5 mm.
  
  Fig 3: Identifying Ring To Shift Sleeve Dimension
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Insert the spring into the loose gear wheel so that the angled end engages in the bore.

Fig 4: Locating Gear Wheel Spring
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Install operating sleeves in correct position. The slanted side -1- is facing the loose gear wheel for reverse gear in the case of the operating sleeve for 5th and reverse gear. The slanted side is facing the loose gear wheel for 2nd gear in the case of the operating sleeve for 1st and 2nd gear.

Fig 5: Locating Operating Sleeve
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Determine the circlip for the taper roller bearing. To do this, determine the thickest ring that can still be used.

Fig 6: Identifying Taper Roller Bearing Circlip
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Determine the other circlips in the same way.
Information

The thickness of circlips 1, 2, 4, 5 and 7 must be calculated again. Circlips 3 and 6 always have the same thickness. Circlip 3 is 2.5 mm and circlip 6 is 2.0 mm thick.

Arrangement of the circlips:

Fig 7: Identifying Circlips For Output Shaft
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