Disassembly and Assembly of Subassemblies Special Tool(s) | Remover, Bearing (Main Tool) 205-295 (15-050A) | | Collet for 205-295 308-196 (16-061) | | Support Plate, Gear Removal (Dia 81.2 mm) 308-229 (16-076) | | Support Plate, Gear Removal (Dia 85.1 mm) 308-230 (16-077) | Materials Name Specification Manual transmission fluid WSD-M2C200-C Disassembly All vehicles | -
Remove the fifth gear wheel and the roller bearing. - Slide the snap ring up out of the annular grove until it is located below the roller bearing.
- Using the special tool, remove the fifth gear wheel with the snap ring and roller bearing.
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Remove the fourth gear wheel assembly. - Remove the fourth gear wheel.
- Remove the needle roller bearing.
- Remove the synchronizer ring.
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Remove the third and fourth gear synchronizer assembly. - Remove and discard the snap ring.
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NOTE:Take care when removing the selector ring from the synchronizer assembly. The detent balls are spring-loaded. Disassemble the third and fourth gear synchronizer assembly. - Remove the selector ring.
- Remove the compression springs, blocker bars and detent balls.
| Vehicles built up to 08/2001 | -
Remove the third gear double synchronizer. - Remove the outer synchronizer ring.
- Remove the synchronizer cone.
- Remove the inner synchronizer ring.
| Vehicles built 08/2001 onwards | -
Remove the third gear synchronizer. - Remove the synchronizer ring.
- Remove the third gear wheel.
| All vehicles | -
Remove the third gear wheel and needle roller bearing. | | -
Using the special tools, remove the roller bearing. | Assembly All vehicles | -
NOTE:When installing new roller bearings, lubricate the roller bearings after the shimming process. When installing the original roller bearings, check all parts carefully and lubricate them with clean transmission fluid. | | -
Using a length of suitable tube, install the roller bearing. | | -
Install the third gear wheel and the needle roller bearing. | Vehicles built up to 08/2001 | -
Install the third gear double synchronizer. - Install the inner synchronizer ring.
- Install the synchronizer cone.
- Install the outer synchronizer ring.
| Vehicles built 08/2001 onwards | -
Install the third gear wheel. - Install the third gear wheel.
- Install the third gear synchronizer ring.
| All vehicles | -
Assemble the third and fourth gear synchronizer assembly. - Install the compression springs.
- Install the blocker bars and the detent balls.
- Install the selector ring.
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NOTE:Install the third and fourth gear synchronizer assembly with the larger collar facing outwards (towards the fourth gear wheel). NOTE:Install a new snap ring. Install the third and fourth gear synchronizer assembly. - Install the synchronizer assembly.
- Install the snap ring.
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Install the fourth gear wheel assembly. - Install the synchronizer ring.
- Install the needle roller bearing.
- Install the fourth gear wheel.
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NOTE:Install a new snap ring. NOTE:Install the fifth gear wheel with the larger collar facing outwards. Using a length of suitable tube, install the fifth gear wheel. - Install the fifth gear wheel.
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Using a length of suitable tube, install the roller bearing. | |