Assembly Instructions For Drive Shaft

Information 

Circlips of different sizes and thicknesses are used. For this reason, the individual circlips must be marked (e.g. with numbers). The thickness of the circlip must be determined again if a directly affected component is replaced.

Information 

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

1. Check the synchronizer rings 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 1: Identifying Ring To Shift Sleeve Dimension

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2. Insert the spring into the loose gear wheel so that the angled end engages in the bore.
   Fig 2: Locating Gear Wheel Spring

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3. Fit operating sleeve so that the slant -1-  is facing 4th gear and the offset side -2-  is facing 3rd gear.
   Fig 3: Locating Operating Sleeve

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4. Determine the circlip for 4th gear. To do this, determine the thickest ring that can still be used.
   Fig 4: Identifying Circlip For 4th Gear

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5. Determine the circlip for 5th gear in the same way as for 4th gear.
6. Heat the synchronizing hubs for 3rd and 4th gear to approx. 100 °C and press onto the drive shaft. The high collar is facing the loose gear wheel for 3rd gear.
   Fig 5: Pressing On Synchronizing Hub

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7. Heat the fixed gear wheel for 5th gear to approx. 100 °C and press onto the drive shaft. The high collar is facing reverse gear and the oil pockets are facing 4th gear.
   Fig 6: Pressing On Fixed Gear Wheel

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