Removal / Installation

Transfer And Intermediate Casing Removal/Installation (Part 1 Of 5):

Transfer And Intermediate Casing Removal/Installation (Part 2 Of 5):

Transfer And Intermediate Casing Removal/Installation (Part 3 Of 5):

Transfer And Intermediate Casing Removal/Installation (Part 4 Of 5):

Transfer And Intermediate Casing Removal/Installation (Part 5 Of 5):

Disassembly And Assembly Notes





NOTE: If the shift rods are moved across the neutral or gear latching positions when the transmission is dismantled or assembled, the small intermediate locks may drop out inadvertently.

Disassembly





1. Engage 6th gear, lock drive shaft with Special Tool 9253 and unscrew hexagon head nuts for output and input shafts.





2. Engage 4th gear and pull off inner race of needle roller bearing (5th gear).

Assembly





1. Check synchronizing rings by pushing rings onto tapers of gearwheels and measuring gap ,A" with a feeler gauge.
- Installation dimension:
New: 0.9 mm minimum
Wear limit: 0.6 to 0.7 mm
2. Engage 4th gear and fit all gearwheels.





3. Adjust inner shift rod until all gears may be preselected freely without notching.
- To adjust, undo hexagon head bolts of tensioning plate and rotate eccentric bushing.
4. To check, shift through all gears, using a long M 8 bolt that is screwed into the inner shift rod.