Output Shaft: Service and Repair

DISASSEMBLING:

NOTE:
It is recommended to mark synchromesh rings and their corresponding gear wheels when disassembling the output shaft, in order to avoid mixing up synchromesh rings.
Care must be taken with the needle bearing for each gear so as not to mix them up or dislodge the bearings from their cage.





- Pull off input shaft (1), synchromesh ring (2) and needle bearing (3).





- Remove snap ring (4).
- Remove washer (5).

Installation Note:
Adjust play between snap ring and guide sleeve to 0.0 - 0.09 mm (0 - 0.0035 in).
Always replace snap ring.





- Pull off guide sleeve, synchromesh ring, 3rd gear and needle bearing.





- Press 2nd gear, needle bearing, synchromesh ring, guide sleeve, synchromesh ring, 1st gear, needle bearing with bearing sleeve and bearing inner race off of output shaft.
- Check condition of all bearings, replacing it necessary
- Check synchromesh rings.





- Install needle bearing, 2nd gear, synchromesh ring and guide sleeve with offset groove facing 1st gear.
- Install bearing sleeve and needle bearing in 1st gear.
- Install synchromesh ring.
- Press on output shaft.

NOTE: Guide in synchromesh ring with tabs in sliding sleeve.





- Heat bearing inner race (7) to approx. 80°C (175°F) with a hot air blower and install on output shaft, pressing on with Special Tool 23 1 440 if necessary.

Determine Thickness Of Shim X:





- Measure distance (A) from collar of output shaft to bearing inner race.





- Place bearing sleeve for reverse gear in guide sleeve.
- Measure distance (B) from collar of guide sleeve to bearing sleeve.

EXAMPLE:
A 52.2 mm (2.055 in)
- B 52.0 mm (2.047 in)
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X 0.2 mm (0.008 in) shim thickness