Bearing housing, dismantling and assembling

The gearbox remains in place.

Note

Micro-encapsulated bolts. If the bolts are difficult to unscrew, warm the bearing housing to about 80 ° C with a warm air gun

Note

Micro-encapsulated bolts. If the bolts are difficult to unscrew, warm the bearing housing to about 80 ° C with a warm air gun

Note

Micro-encapsulated bolts. If the bolts are difficult to unscrew, warm the bearing housing to about 80 ° C with a warm air gun

Tap out the retention pin (3) from the 1st/2nd gear selector fork (4) with KM-308

Remove the selector fork with the selector rod

Warning: Take hold of the main shaft, drive shaft and the reverse-gear pinion.

Remove the bearing housing from KM-552

Press out the main shaft and drive shaft with KM-6335 (1) as illustrated

Note: In order that both shafts may be pressed out evenly, the press anvil must be located more towards the main shaft.

Take hold of the main shaft, drive shaft and reverse idler gear

Important: Watch out for the detent balls which will be released.

Hold the reverse idler shaft in a vice with suitable jaw grips

Carefully tap the bearing cover with a brass drift

2x Remove the circlips (2).

2x Press out the bearings with KM-500-5 or alternatively 87 92 210 Support, differential bearing (3).

Check all parts for wear, pitting or damage. Replace if necessary.

2x Press in the bearing with KM-523-1 (1) and KM-6336 or alternatively 87 92 475 Press sleeve, differential bearing (2)

2x Fit the circlip (3)

Caution: Check that the circlips are correctly located.

Important: Check that the shafts are correctly located.

Place the bearing housing (4) on KM-6338 (5)

Position the main shaft (1) and the drive shaft (3) in the bearing housing

Caution: Pay attention to the assembly arrangement

Press in the main shaft and the drive shaft with KM-6338 and KM-6337 (2)

Important: Note the assembly arrangement

Put the reverse idler gear on the shaft

Caution: Note the orientation, the selector fork track is uppermost.

Push the reverse idler gear shaft, with the detent ball (arrowed) inserted, in until it seats in the bearing cover

Place the bearing cover on KM-6337 (3)

Press the bearing sleeve onto the main shaft with KM-6339 or alternatively 87 91 196 Ring, bearing race (2)

Fit the bearing housing on KM-552

Fit the bearing cover with KM-552 on KM-113-2

Insert the pin for the interlock between 3rd/4th gear and reverse gear

Important: In order to reduce the loading on the selector rod guide in the bearing house, the selector rods must be supported with a wooden wedge when inserting the pins.

Insert the reverse gear selector fork (5) and selector rod (6)

Insert a new retention pin with KM-308 or a suitable drift (4)

Caution: Let the retention pin stick out about 2 mm (dimension l).

Important: In order to reduce the loading on the selector rod guides in the bearing house, the selector rods must be supported with a wooden wedge when inserting the pins.

Insert the 1st/2nd gear selector fork (3) and selector rod (2)

Insert a new retention pin with KM-308 or a suitable drift (4)

Caution: Let the retention pin stick out about 2 mm (dimension l).

Important: In order to reduce the loading on the selector rod guides in the bearing house, the selector rods must be supported with a wooden wedge when inserting the pins.

Fit the 3rd/4th gear selector fork (2) and selector rod (1)

Insert a new retention pin with KM-308 or a suitable drift (3)

Caution: Let the retention pin stick out about 2 mm

Fit the four locking plugs (5, 6 and 7)

Note: Drive them home with a plastic hammer or soft metal drift.

Note: Turn the bearing housing on its side.

Position the interlock pin bridge (2) on the bearing housing

Fit the two screws (1) with thread locking compound

Caution: do not tighten yet.

Position the 3rd/4th gear selector fork in the neutral position

Tighten the two screws (1) (7 Nm)

Move the selector forks to the neutral position

Position the holder

Fit the two screws (arrowed) with thread locking compound

Tighten the two screws (arrowed) (7 Nm)

Important: Note the assembly orientation. The long pinion hub points towards the bearing housing.

Fit the bearing housing with main shaft and drive shaft in KM-6337 (3)

Press on the 5th gear pinion with KM-334 or alternatively 87 91 196 Ring, bearing race (1)

Fit a new circlip (4)

Caution: The circlip must be securely snapped into place.

Wet the needle bearings (6) with gearbox oil and put them onto the main shaft

Caution: Check that the needle bearings are correctly located.

Assemble the 5th-gear pinion and baulk ring on the main shaft

Put the bearing housing in KM-6337

Put the synchromesh assembly (1) on the main shaft

Important: The tabs on the baulk ring must align with the grooves in the synchromesh assembly.

Press the synchromesh assembly onto the main shaft using KM-334 or a suitable sleeve

Fit a new circlip (2)

Caution: The circlip must be securely snapped into place.

Fit the two sliding keys (arrowed) onto the rocker arm (3) (5th gear selector fork)

Put the pivot bracket with rocker arm onto the bearing housing

Fit the two screws with thread locking compound

2x Tighten the screws (22 Nm)

Fit the thrust washer with grease

Important: Before the bearing housing is assembled to the gearcase the mounting and positioning of the following components should be checked: Selector fork, 3rd/4th gear (1), Selector rod, 3rd/4th gear (2), Selector dog, 5th gear (3), Selector rod, 1st/2nd gear (4), Selector fork, 1st/2nd gear (5), Interlock pins (6), Selector fork, reverse gear (7), Selector rod reverse gear (8)

Remove the bearing housing from KM-552

See Bearing housing cover gasket, replacement F17

See the service procedure " Gear change cover, removal and fitting and/or sealing (F 17)"

See Checking and correcting the gearbox oil level F17

Assemble with a new sealing ring

Tighten the reversing light switch (20 Nm)

Replace the wiring loom connector (4)

Check that the gears may be freely engaged whilst the vehicle is stationary, the engine running and the clutch disengaged