Assembling Gear Wheel Set For 1st-4th Gear

1. 1.1. Clamp the drive shaft -22-  in a vice using special tool Socket-Wrench Insert 9282  .
   Fig 2: Clamping Drive Shaft In Vice Using Special Tool Socket-Wrench Insert 9282

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2. 1.2. Assemble synchronization if necessary.

   Check that the steel synchronizer rings and driver dogs -B-  are seated correctly. The driver dogs with spring and ball must be aligned with the prick punch marks on the shift collar. Also check that the rectangular indentations of the synchronizer rings -A-  are positioned above the driver dogs -B-  .

   Fig 3: Identifying Synchronization

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3. 1.3. Check the synchronizing rings for wear.

   To do this, press the synchronizer rings onto the gear wheel cones using an average amount of force and measure the gap -A-  with a feeler gauge.

   → Nominal value: 0.9 mm 

   → Nominal value: 0.6 mm+0.1 mm 

   Fig 4: Checking Synchronizer Ring Wear

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4. 1.4. Fit needle-roller bearing -21-  , loose gear wheel for 3rd gear -20-  and synchronization on the drive shaft -22-  .
5. 1.5. Install inner bearing ring -13-  .

   Heat inner bearing ring -13-  to → Temperature: 120°C  and fit it on the drive shaft -22-  .

6. 1.6. Fit loose gear wheel for 4th gear -10-  with needle-roller bearing -12-  and thrust washer -9-  on the drive shaft -22-  .

   The large flat-ground side of the thrust washer -9- must be facing the loose gear wheel for 4th gear. 

7. 1.7. Install inner bearing ring -6-  .

   Heat inner bearing ring -6-  to → Temperature: 120°C  and fit it on the drive shaft -22-  .

8. 1.8. Fit tensioning plate -5-  with lock -8-  , four-point bearing -4-  and shift fork for 3rd/4th gear -7-  on the drive shaft -22-  .
9. 1.9. Install inner bearing ring -3-  .

   Heat inner bearing ring -3-  to → Temperature: 120°C  and fit it on the drive shaft -22-  .

10. 1.10. Install cylindrical-roller bearing -2-  .

    Heat cylindrical-roller bearing -2-  → Temperature: 120°C  and fit it on the drive shaft -22-  .

11. 1.11. Tighten (self-locking) nut -1-  for drive shaft.

    Screw on and tighten new (self-locking) nut -1-  on the drive shaft -22-  .

    → Tightening torque: 250 Nm (185 ft. lb.) 

    Fig 5: Overview Of Middle Gear Wheel Set

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    1. Cylindrical-roller bearing
    2. Thrust washer
    3. Loose gear wheel, 1st gear
    4. Friction ring
    5. Cone ring
    6. Synchronizer ring
    7. Needle-roller bearing
    8. Inner bearing ring
    9. Shift sleeve
    10. Guide sleeve
    11. Spring
    12. Ball
    13. Driver dog
    14. Synchronizer ring
    15. Cone ring
    16. Friction ring
    17. Loose gear wheel, 2nd gear
    18. Needle-roller bearing
    19. Inner bearing ring
    20. Thrust washer
    21. Fixed gear wheel, 3rd gear
    22. Oil pipe
    23. Lock
    24. Shift rod (1st/2nd gear)
    25. Intermediate lock
    26. Shift rod (reverse gear)
    27. Shifting shaft
    28. Shift rod (5th/6th gear)
    29. Tensioning plate
    30. Nut
    31. Shift rod (3rd/4th gear)
    32. Cylindrical-roller bearing
    33. Screw plug
    34. Spring
    35. Ball
    36. Adjusting shim S3
    37. Transmission housing
    38. (not used for Turbo)
    39. Fixed gear wheel, 4th gear

Information 

Whether or not the ring gear and pinion shaft needs to be replaced depends on which components have to be replaced and the reason why the transmission was disassembled in the first place.

The purpose of the adjustment operations is to re-establish the maximum smooth running level, which was determined in production on a testing machine.

The ring gear and pinion shaft must be adjusted when the following components are replaced:

• Drive and output shafts 
• Drive and output shaft bearings 
• Final drive and its bearings 

The ring gear and pinion shaft does not generally have to be adjusted. 

Insert drive shaft -A-  with adjusting shim S5 -B-  and adjusting shim S4 -C-  into the tensioning plate -F-  .

Fig 6: Identifying Installing Input And Output Shafts

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1. 3.1. Fit fixed gear wheel for 4th gear -D-  on the output shaft.

   The large collar must be facing the tensioning plate.

2. 3.2. Affix adjusting shim S3 -A-  in the transmission housing with viscous grease.
   Fig 7: Adjusting Transmission Housing Shim

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3. 3.3. Install tensioning plate with the input and output shafts.

   Insert tensioning plate with input and output shafts into the transmission housing and screw on the nuts -1-  .

   → Tightening torque: 25 Nm (19 ft. lb.) 

   Fig 8: Identifying Tensioning Plate

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Fit oil pipe -3-  and screw in screws -1, 2-  .

→ Tightening torque: 6 Nm (4.5 ft. lb.) 

Fig 9: Identifying Oil Pipe

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→ 394019 REMOVING AND INSTALLING DIFFERENTIAL WITH DIFFERENTIAL LOCK - section on "Installing"

Fig 10: Overview Of Differential Lock

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The large collar on the fixed gear wheel for 3rd gear -21-  must be pointing towards the thrust washer -20-  .

1. 7.1. Fit thrust washer -20-  on the output shaft.
2. 7.2. Heat inner bearing ring -19-  to → Temperature: 120°C  and fit it on the output shaft.

   Fit needle-roller bearing -18-  on the inner bearing ring -19-  .

To do this, place the friction ring -16-  , the cone ring -15-  and the synchronizer ring -14-  on the gear wheel. Measure the gap -A-  with a feeler gauge. Perform test for 1st and 2nd gear.

Fig 11: Checking Synchronizer Ring Wear

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Information 

• The prick punch marks on the shift sleeve must be centered with respect to the recesses in the guide sleeve. 

  The groove -A-  in the shift sleeve must be facing the loose gear wheel for 2nd gear -17-  .

  Fig 12: Identifying Shift Sleeve

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1. 9.1. Fit loose gear wheel for 2nd gear -17-  on the needle-roller bearing.
2. 9.2. Insert friction ring, cone ring and synchronizer ring -14, 15, 16-  in the guide sleeve -10-  .
3. 9.3. Fit ball, driver dog and spring -2, 3, 4-  .

   To do this, slide the shift sleeve -9-  towards the loose gear wheel for 2nd gear -17-  .

   Fig 13: Identifying Synchronization

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4. 9.4. Fit synchronizer ring, cone ring and friction ring -4, 5, 6-  .

Information 

When removing and installing gear wheel sets and shift rods, the small synchronization parts (balls, driver dogs, springs in the locking mechanism -2, 3, 4-  ) can pop out when you move them. We recommend the following approach:

Make sure not to change the zero position of the shift sleeve -1-  during removal and insert the complete gear wheel set with loose gear wheels during installation.

Fig 14: Identifying Synchronization

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1. 10.1. Install inner bearing ring.

   Heat inner bearing ring -8-  to → Temperature: 120°C  and fit it on the output shaft.

   Fit needle-roller bearing -7-  on the inner bearing ring -8-  .

2. 10.2. Install gear wheel set for 1st-2nd gear.

   In doing so, the cut-out on the inner toothing of the guide sleeve -10- must be flush with the oil bore on the output shaft. 

   Install shift rod for 1st-2nd gear -24-  with gear wheel set for 1st-2nd gear.

3. 10.3. Fit loose gear wheel for 1st gear -3-  and thrust washer -2-  onto the output shaft.

Heat cylindrical-roller bearing -1-  to → Temperature: 120°C  and fit it on the output shaft.

Heat cylindrical-roller bearing -32-  to → Temperature: 120°C  and fit it on the drive shaft.

1. Shift rod for 3rd/4th gear
2. Lock (short)
3. Shift rod for 5th/6th gear
4. Intermediate lock
5. Lock (long)
6. Shift rod for reverse gear
7. Intermediate lock
8. Lock (short)
9. Shift rod for 1st/2nd gear
   Fig 15: Identifying Shift Mechanism

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Affix locks -2, 4, 5, 7, 8-  with viscous grease if necessary. Check that the rollers on the shifting shaft are complete.

Information 

• Do not move the shift rods past the neutral lock or gear lock during or after fitting as otherwise the small locking elements and the balls of the lock can fall into the transmission. 

→ Tightening torque: 20 Nm (15 ft. lb.) 

Fit springs and balls and tighten the screw plugs -1-  .

Fig 16: Identifying Screw Plugs

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Coat transmission housing with Loctite 574 and fit it. To do this, insert shift rods into suitable bearing locations and ensure that the shift catch roller engages correctly in the driver of the shifting shaft.

→ Tightening torque: 23 Nm (17 ft. lb.) 

Fit locking pin and spring and tighten the screw plug -1-  .

→ Tightening torque: 23 Nm (17 ft. lb.) 

Fig 17: Identifying Screw Plug On Transmission

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