Dismantling and assembling tensioning plate

No.

Designation

Removal

Installation

1

Straight pin

4

With the shift rods fitted, the springs (No. 3) are under load

2

Washer

4

3

Thrust spring

4

4

Locking bush

4

5

Lock (long)

1

6

Lock (short)

1

7

Lock (short)

1

8

Roll pin

1

9

Bearing shaft

1

Install in correct position, use 8 mm dia. locating mandrel to locate relative to tensioning plate hole

10

Ball

1

11

Thrust spring

1

12

Deflection lever

1

13

Thrust spring

1

Mark for reinstallation

Free length = 51.3 + 0.5 mm wire thickness = 1.5 mm. Do not cnfuse with spring No. 14

14

Thrust spring

1

Mark for reinstallation

Free length = 72.6 + 0.5 mm wire thickness = 1.1 mm. Do not confuse with spring No. 13

15

Shim

2

No.

Designation

Removal

Installation

Washer

Selector gate

Adapter sleeve with snap ring

Tensioning plate

1

Press out with suitable drift

Tighten to 10 Nm (7 ftlb.

Press in with suitable drift until it is seated against the stop

<

Installation position of the locks

1709-35

35 40 19 Removing and installing input shaft

Tools

35 40 19 Removing and installing input shaft

No.

Designation

Qty.

Removal

Note:

I Installation

5

Cylindrical roller bearing Shift rod (5th and 6th gear)

Spacer

Inner race

Thrust washer

1

Shift rods in neutral position

Coat with stiff grease to insert

Fit with the same gearwheel. Heat to approx. 120 °C

6 7

Cylindrical roller bearing Thrust washer

1 1

Heat to approx. 120 °C

8

Loose gearwheel (1st gear)

1

9

Friction ring

1

Fit with the same gearwheel

10

Tapered ring

1

Fit with the same gearwheel. Tabs must engage into the cutouts in the loose gearwheel

11

Synchronizing ring

1

Check for wear. Fit with the same gearwheel. Drivers must engage in the cutouts in the tapered ring. Three lugs face the driver dogs.

12

Needle roller bearing

1

Fit with the same gearwheel

13

Inner race

1

Fit with the same gearwheel. Heat to approx. 120 °C

No,

Designation

Removal

Installation

14

Shift sleeve

1

Insert complete with guide sleeve and shift rods. Make sure the missing tooth of the internal teelh of the guide sleeve (No, 21) is aligned exactly above the oil bore of the output shaft. The circumferential identification groove must face 2nd gear. The centerpunch marks must be centered relative to the balls (see page 35-213)

15

Shift rod with pinned shift fork

1

16

Shift rod (reverse)

1

17

Intermediate lock

1

Coat with stiff grease to insert

18

Driver dog

3

Install in correct position

19

Ball

3

20

Spring

3

21

Guide sleeve

1

Missing tooth of the internal splines must be exactly above the oil bore of the output shaft

22

Synchronizing ring

1

Check for wear. Fit with the same gearwheel. Drivers must engage into the cutouts in the tapered sleeve. Three lugs face the driver dogs.

35 40 19 Removing and installing input shaft

35 40 19 Removing and installing input shaft

Printed in Germany - 20, 1997

35 40 19 Removing and installing input shaft

Printed in Germany - 20, 1997

No.

Designation

Qty.

Removal

Note:

Installation

40

Four-point bearing

1

41

Output shaft

1

Insert complete with pinned shift rod / shift fork (No. 42)

42

Shift rod with pinned shift fork

1

43

Lock (short)

1

44

Lock (long)

1

45

Lock (short)

1

---

1

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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