Output Shaft

Output Shaft





Special Tool(s)

Disassembly





1. CAUTION: Handle the dual synchronizer parts with care.

Remove the ball bearing and the fourth gear wheel.
1 Remove the small snap-ring.
2 Install the snap-ring.
3 Using a standard puller, remove the ball bearing.
4 Remove the fourth gear wheel together with the synchronizer ring.





2. Remove third and fourth gear synchronizer unit.
1 Remove the snap-ring.
2 Remove the gear synchronizer, the third and fourth gear synchronizer unit and the third gear wheel.





3. Remove the third gear synchronizer ring.
1 Synchronizer ring.
2 Gear wheel (third gear)





4. NOTE: The dual synchronizer as shown is used in case off servicing.

Disassemble the third gear synchronizer unit.
1 Outer synchronizer ring
2 Synchronizer cone
3 Inner synchronizer ring
4 Gear wheel (third gear)





5. Remove the second gear wheel together with the synchronizer unit.
1 Closed retaining ring
2 Half-round snap rings
3 Gear wheel (second gear)
4 Inner synchronizer ring
5 Synchronizer cone
6 Outer synchronizer ring





6. NOTE: Remove the synchronizer unit and the first gear wheel together.

Remove the first gear wheel and the reverse gear wheel together with the gear synchronizer and the synchronizer unit.
1 Remove the snap-ring.
2 Remove the first/second gear synchronizer together with the reverse gear wheel.
3 Outer synchronizer ring
4 Synchronizer cone
5 Inner synchronizer ring
6 Gear wheel (first gear)





7. CAUTION: Mark the installation position of the selector ring in relation to the gear synchronizer hub.

Disassemble the synchronizer hub.
1 Selector ring
2 Synchronizer spring
3 Synchronizer lock
4 Gear synchronizer hub





8. NOTE: Insert a pressure piece into oil the thrower bore.

Using the special tools, remove the output shaft bearing cone.
1 Remove the snap-ring.
^ Position the special tool 307-217 below of the bearing cone.
2 Remove the bearing cone.

Assembly

CAUTION: Immerse the dual synchronizer units in a bath of transmission fluid prior to installation.

1. Carefully clean and check all running surfaces and coat them with Manual transmission fluid before reassembly.





2. NOTE: Install a new snap ring.

Install the output shaft bearing cone.
^ Evenly heat the bearing cone to approximately 80°C and slide it onto the output shaft.
^ Install the snap-ring.





3. NOTE: Marking of selector ring installation position in relation to gear synchronizer hub.

Assemble the gear synchronizer.
1 Gear synchronizer hub
2 Install the selector ring onto gear synchronizer hub.
3 Insert the synchronizer lock.
4 Insert the synchronizer spring.





4. NOTE: Install a new snap ring.

Install the first gear and reverse gear wheel onto the output shaft together with the gear synchronizer and the synchronizer unit.
1 Gear wheel (first gear)
2 Inner synchronizer ring
3 Synchronizer cone
4 Outer synchronizer ring
5 First/second gear synchronizer with reverse gear wheel
6 Snap-ring





5. NOTE: Re-assemble synchronizer unit prior to installation.

NOTE: Install new half round snap rings.

Install the second gear wheel onto the output shaft together with the synchronizer unit.
1 Outer synchronizer ring
2 Synchronizer cone
3 Inner synchronizer ring
4 Gear wheel (second gear)
5 Half-round snap-rings
6 Closed retaining ring





6. NOTE: The dual synchronizer as shown is used in case of servicing.

Assemble the third gear synchronizer unit.
1 Gear wheel (third gear)
2 Inner synchronizer ring
3 Synchronizer cone
4 Outer synchronizer ring





7. Install the third gear synchronizer ring.
1 Synchronizer ring.
2 Gear wheel (third gear)





8. NOTE: Install the selector ring with annular groove facing downwards and small hub collar facing upwards.

NOTE: Install a new snap ring.

Install the third/fourth gear synchronizer unit
1 Install the gear synchronizer, the third/fourth gear synchronizer unit and the third gear wheel.
2 Install the snap-ring.





9. NOTE: Install the ball bearing with annular groove facing outwards.

NOTE: Install a new snap ring.

Install the fourth gear wheel and the ball bearing.
1 Install the synchronizer ring together with the fourth gear wheel.
2 Using a press and a suitable tube, press on the ball bearing.
^ Install the snap-ring.