Removing and installing 5th and 6th gear

No.

Designation

Removal

Installation

1

Cover

1

Use a large screwdriver to lever out. The oil catcher is damaged in the process

Replace

2

Oil catcher

1

Lever out at bore using a screwdriver

Replace. Observe installation position

3

Bolt

1

Lock drive shaft, removing shift cylinder and engaging two gears

Tighten to 150 Nm (111 ftlb)

4

Four-point bearing inner race

1

Pull out using thrust piece 9535 and internal puller 30...37 mm (e.g. Kukko 21/5)

Heat to approx. 100°C and drive into place

5

Bolt M 8 x 60"

7

Tighten to 25 Nm (18 ftlb)

6

End cap

1

7

Gasket

1

Replace

8

Adapter sleeve

2

9

Lock ring

1

10

Fixed gear, 5th gear

1

Engage 2 gears and pull off using two-way puller

Heat to approx. 120°C and drive in to stop, observing correct installation position. Installation position: Flange towards gearwheel for 6th gear

11

Four-point bearing inner race

1

Pull off across 5th gear loose gearwheel (No. 13), using thrust piece 9536 and two-way puller

Heat to approx. 100°C and drive in to stop

12

Needle-roller bearing

1

Mark for reinstallation

Oil with transmission oil. Fit with the same gearwheel as before

13

5th gear loose gearwheel with spring

1

14

Synchronizing ring

1

Mark for reinstallation

Check for wear.

Fit with same gearwheel as before.

No.

Designation

Removal

Installation

15

Spiral pin

1

Press out only with Special Tool 3276

Press in only with Special Tool 3276

16

Selector sleeve

1

Mark for reinstallation along with synchronzier hub. Pull off shift rod along with shift fork and dog

Marks on synchronizer hub and selector sleeve must match

17

Shift fork

1

18

Driver

1

Replace only complete with shift rod for 5th and 6th gear

19

Bearing inner race

1

Pull off across 6th gear loose gearwheel (No. 22) using thrust piece 9536 and two-way puller

Heat to approx. 100°C and drive in until it is seated at the stop

20

Synchronizer hub

1

Pull off along with bearing Inner race (No. 19)

Heat to approx. 100°C and press in to stop, observing correct position

21

Synchronizing ring

1

Mark for reinstallation

Check for wear, fit with the same gearwheel as before

22

6th gear loose gearwheel with spring

1

23

Needle-roller bearing

1

Mark for reinstallation

Oil with transmission oii. Fit with the same gearwheel as before

24

Thrust washer

1

Cutout points towards snap ring

25

End shield

1

If the height of the lug (approx. 35 mm) at the end cap is insufficient, a washer must be inserted at both of the lowermost bolts (No. 5).

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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