Dismantling and assembling notes Note

Since 1 October 1994, the fixed wheel of second gear (no. 22) has been firmly fixed to the drive pinion; the needle cage (no. 19) runs directly on the polished shaft. The thrust washer (no. 21) and the inner ring (no. 20) are no longer fitted.

Dismantling

1. Mount retaining plate 9282 in vise, fit input shaft and undo hexagon-head nut with Special Tool 9105.

535-35

2. Use a suitable tool (e.g. Kukko 17 -1) to press all parts off the input shaft over the 2nd gear wheel.

Assembling

1. To inspect synchronizing rings, press rings onto the gear wheel tapers and use a feeler gauge to measure gap "A".

Assembly dimension (new) = 0.9 mm min. Wear limit = 0.6 to 0.7 mm

518-35

Note

Transmission shafts without recesses for securing the hexagon nuts have been installed since September 1995.

Self-locking hexagon nuts are used on these shafts, and these nuts must always be replaced in every transmission repair.

35 40 37 Dismantling and assembling input shaft

Printed In Germany - 20. 1997

35 59 37 Dismantling and assembling output shaft

1698-35

No.

Designation

Removal

Installation

1

Bearing inner race

1

Mark for reinstallation, press off with suitable separating device (e.g. Kukko 15-17)

Do not confuse with inner race No. 3 , heat to ap-prox. 120 °C and press into place

2

Four-point bearing

1

3

Bearing inner race

1

Mark for reinstallation, press off with suitable separating device (e.g. Kukko 15-17)

Do not confuse with inner race No. 1, heat to ap-prox. 120 °C and press into place

4

Cylindrical roller bearing

1

Press off with suitable separating device (e.g. Kukko 15 -17)

Heat to approx. 120 °C and press into correct position using a suitable pipe section (e.g. VW 519)

5

Output shaft

1

Observe matching number. Readjust if required

35 75 19 Removing and installing 5th gear (transmission is i

No.

Designation

Removal

Installation

1

Hexagon-head boll

2

Tighten to 10 Nm (7 (lib.)

2

Washer

2

3

Clamping plate

1

4

Eccentric bushing

1

Adjust

5

Seal

1

Replace

6

Thrust spring

1

7

Locking bush

1

B

Hexagon head nul

10

Tighten to 23 Nm (17 ftlb,)

9

Washer

10

10

Front transmission cover

1

Remove complete with transmission support

11

Gasket

1

Replace

12

Hexagon nut*

1

Engage 4th gear and apply handbrake

Replace. Tighten lo 300 Nm (221 ftlb.), Upsel flange to lock

13

Hexagon nut*

1

Engage 4th gear and apply handbrake

Repiace. Tighten to 200 Nm (147 ftlb.). Upset flange to lock

14

Bearing inner race

1

Pull off across fixed gearwheel No, 15

Heal to approx. 120 CTC

15

Fixed gearwheel (reverse)

1

15

Spacer sleeve

1

17

Cylindrical roller bearing

1

Pull off across loose gearwheel No. 19

Heat to approx. 120 °C

18

Thrust washer

1

Loose gearwheel (reverse)

1

-- oh ni>ar (transmission is installed)

Note:

No.

Designation

Qty.

Removal

Installation

30

Synchronizing ring

1

Mark for reinstallation

Check for wear. Fit with the same gearwheel.

31

Needle-roller cage

' ■ - - »Ii

\

Mark for reinstallation

Cogs face driver dogs. Fit with the same gear

X " )

fsi'-y

wheel.

* Transmission shafts without recesses for securing the hexagon nuts have been installed since September 1995.

Self-locking hexagon nuts are used on these shafts, and these nuts must always be replaced in every transmission repair.

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