Dismantling and assembly notes

Dismantling

To facilitate assembly, do not remove the complete gear set assembly but partially dismantle the installed drive pinion.

2. Engage 4th gear and assemble fully preas sembled gear set to internal selector rod.

Assembly

1. The number of adjusting shims "S3" noted during dismantling or the number of adjusting shims noted when the drive pinion was adjusted should be placed onto the studs in the housing until the equivalent thickness is obtained.

3. Tighten tensioning plate lock nuts to 23 Nm (17 ftlb).

Ca (993

Manual insi is*! antmls

34 SO 37 Dismantf ig id ssembl termed at& casi

Ools

Ools

No.

Designation

Special tool

Order number

Explanation

Mandrel

9254

000.721.925.40

" • 1 1 —-.-f.r'i-v.ni'i

Dismantling and assembling intermediate casing

No.

Designation

Removal

Installation

: ' ffi'-a

t

Hexagon head bolt with

- 1

Ma = 23 Nm (17 ftlb.)

washer

Pin with roll pin

wh te ■

2

1

rjfcb .A

Install in correct position

3

Reverse idler gear

1

Small flange faces hexa

gon head bolt (item No. 1)

4

Thrust washer (2.0 mm

1

thick)

- ■

5

Thrust washer (1.5 mm

Do not confuse with

thick)

■f •

washer No. 4

6

Thrust washer (1,5 mm

■ t . 4 r ■■ Zm

Do not confuse with

thick)

-

r V,' A,

washer No. 4

7

Needle roller assembly

-

8

Ball sleeve

1

Push out with suitable drift

Working from inside,

or a length of pipe (e.g.

press in flush across let

VW 423)

tered side using 9254

9

Snap ring

10

Bearing outer race

1

Heat housing to approx.

Heat housing to approx.

120 °C

120 °C

11

Snap ring

5 J

12

Cylindrical roller bearing

Heat housing to approx.

As No. 10

120 °C and pull out with

• 4

suitable internal puller

(e.g. Schrem 30 - 40)

13

Housing

1

1. Reassemble reverse idler gear with thrust washers and bolt in correct position (refer to exploded view). With thrust washers and bolt located correctly, the end clearance of the reverse idler gear is 0.15...0.35 mm.

520-34

A = Feeler gauge

2. Check end clearance of reverse idler gear with feeler gauge.

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