Assembling

Note: When replacing tapered roller bearings, check installed position of pinion shaft (actual location) before removing the gear carrier.

Exploded View:

Description:

Assembling

1. Heat inner race for tapered roller bearing to about 120°C (250°F) and press on.

2. Press on 4th gear, whereby collar faces 3rd gear.

Note: It is essential to keep to the following procedures, since the press fit gear takes the engine torque. Clean gear and shaft with a greaseless cleaning solution to remove all oil and grease, and heat gear on a hot plate to about 120°C (250°F). Press on gear and press again after transfer of heat (approx. 3 minutes).

3. Adjust axial play on 4th gear (gear must be cold and pressed against stop). Measure and install the thickest possible circlip. Axial play may be max. 0.02 mm.

Note: Perform work very conscientiously, since otherwise service life of tapered roller bearings could be impaired.

Circlips available:

4. Press on 3rd gear with collar facing 2nd gear.

Note: Clean gear and shaft with a greaseless cleaning solution to remove all oil and grease, and heat gear on a hot plate to approx. 120°C (250°F).

5. Adjust axial play on 3rd gear. Measure axial play on 3rd gear with a feeler gauge blade and correct to 0...0.04 mm by selecting a pertinent circlip. Lower value would be ideal.

Circlips available:

6. Assemble sliding sleeve and synchronizer body for 1st and 2nd gears. It is not necessary to have a pair in a certain position. Insert locks and install springs with 120° offset. Spring must have its angled end engaging in hollow lock.

Note: Coat molybdenum coated synchromesh rings with an approved transmission oil.

7. Press on sliding sleeve with synchronizer body. Turn synchronizer ring so that grooves are aligned with locks.

8. Adjust axial play on synchronizer body. Measure axial play of synchronizer body with a feeler gauge blade and correct to a value between 0 and 0.04 mm by selecting pertinent circlip. Lower value would be ideal.

Circlips available:

9. Press on inner race for tapered roller bearing.

10. Measure play on 1st gear. Play should be between 0.10 and 0.40 mm. Recheck adjustment of synchronizer body if necessary. Parts must be pressed on against stop!