End Shield, Disassemble and Assemble F 10/F 13/F 18/F 18+/F 20 Illustration
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1 |
Drive shaft |
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2 |
Main shaft |
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3 |
Teflon bushing |
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4 |
1st/2nd gear shift fork |
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5 |
Roll pin |
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6 |
1st/2nd gear shift rod |
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7 |
Teflon bushing |
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8 |
Roll pin |
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9 |
3rd/4th gear shift fork |
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10 |
3rd/4th gear shift rod |
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Illustration (Continued)
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11a |
5th gear shift driver (not F 18) |
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11b |
5th gear shift driver (F 18) |
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12 |
Teflon bushing |
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13 |
Teflon bushing |
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14 |
Bearing support |
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15 |
Pin |
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16 |
Rocker arm |
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17 |
Sliding block |
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18 |
Bridge with locking pin |
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19 |
Sliding block |
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Illustration (Continued)
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20 |
Bolt M8 |
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21 |
Bolt M7 |
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22 |
Bolt |
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23 |
End shield cover |
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24 |
Gasket |
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25 |
Retaining ring |
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26 |
5th gear synchromesh body |
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27 |
Synchroniser spring |
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28 |
5th gear shift sleeve |
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29 |
5th gear synchroniser ring |
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Illustration (Continued)
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30 |
5th gear (driven) |
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31 |
Needle bearing |
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32 |
Retaining ring |
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33 |
Thrust washer |
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34 |
Retaining ring |
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35 |
5th gear (driving) |
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36 |
Magnet |
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37 |
Stop plugs |
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Illustration (Continued)
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38 |
Ball |
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39 |
Reverse gear shaft |
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40 |
Reverse gear |
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41 |
Thrust washer |
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42 |
Reverse gear shift fork |
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43 |
Roll pin |
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44 |
Reverse gear shift rod |
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45 |
Pawl |
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46 |
Stop plugs |
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 Remove, Disconnect Remove End Shield - see operation "Gasket for End Shield, Replace". Remove reverse gear thrust washer - note installation position.
 Important! Fasten end shield to transmission block, KM-552, KM-113-2.
Remove, Disconnect | 
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Bearing support with rocker arm from end shield (arrows)
Important! Micro-encapsulated bolts, if stiff warm end shield with blower to ca. 80 ° C (Check temperature with thermocolour rods if available, or use applicable temperature measurement device). | 
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Remove, Disconnect Simultaneously fit retaining ring in front of synchromesh body and in front of transmission shaft synchromesh body 5th gear of transmission shaft, KM-161-A or KM-161-B, KM-161-2 or KM-553-A. 2 gears (e.g. 3nd- and reverse gear). 5th gear (driven). Needle bearing for 5th gear. Needle bearing (for F 16 in two parts) is slotted, bend up slightly. Retaining ring for thrust washer. Thrust washer halves from main shaft. | 
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Remove, Disconnect Retaining ring of gear from gear cluster. Remove retaining ring of 5th gear (driving) from gear cluster, KM-553-A. Place pressure piece on gear cluster.
Important! Do not use axle shaft in gear cluster to support thrust piece. Ensure that remover hooks are correctly seated on gear. | 
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Remove, Disconnect Bearing support with pawl from end shield (arrow). To replace pawl, press out pin from bearing support.
Important! Micro-encapsulated bolts, if stiff, heat end shield with hot-air dryer.
Remove, Disconnect Plugs for switch catch from end shield, KM-727, KM-328-B 1 long plug (1) 3 short plugs (2). | 
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Unbolt bridge for pawl from end shield (large arrows).
Important! Micro-encapsulated bolts, if stiff warm end shield with blower to ca. 80 ° C (Check temperature with thermocolour rods if available, or use applicable temperature measurement device). Engage 2nd and 5th gears (with shift driver). If 3rd gear is now engaged, the bridge will be pushed out. | 
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Remove, Disconnect Spring pins from 3rd/4th gear shift fork and from reverse gear shift fork - drift punch. Release rod guide, support shift rod at top with wooden block. | 
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3rd and 4th gear shift rods and shift forks and also reverse gear from end shield 5th gear shift driver from end shield. Shift sleeve in neutral position. | 
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Remove, Disconnect Locking pin for catch from end shield bore holes. | 
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F 10, F 13-Transmissionn:
Remove, Disconnect Remove retaining rings from grooves in end shield, KM-443-A (2). As assembly aid, tension retaining ring for main shaft with installation plate (1). | 
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Remove, Disconnect Press retaining ring for bearing main shaft together with rounded ring pliers (KM-443-B) and hold under tension with assembly tool (1). Simultaneously press retaining ring for gear cluster bearing apart with flat ring pliers (2) (2nd mechanic). | 
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Pull out main shaft, drive shaft, reverse idler gear, shift fork and shift rod 1st and 2nd gear from end shield. | 
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Remove, Disconnect Clamp reverse gear axle in vice using protective jaws. Drive off end shield carefully, brass drift.
Important! Note that retaining ball is released.
 Clean All parts. | 
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Remove, Disconnect Press reverse gear shaft to stop in end shield with lock ball inserted. Install locking pins for gear lock in end shield bore hole. When replacing 1st/2nd gear shift fork or shift rod: Insert pin in 1st/2nd gear shift fork and shift rod, KM-308/2. Allow new roll pin to project by approx. 2 mm/0.08 in. | 
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 Install, Connect Guide main shaft (1), drive shaft (4), 1st/2nd gear (2) and reverse gear (3) shift forks and shift rods into end shield. Reverse gear shift fork groove points upwards. Lubricate return bore hole with Transmission Fluid. Place thrust washer on reverse gear shaft. Secure main shaft and drive shaft, KM-443-B. Engage new snap rings in grooves. | 
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Insert reverse gear shift rod and shift fork, 3rd/4th gear shift rod and shift fork with 5th gear shift driver in end shield. Support shift rods with block of wood. Secure shift forks and shift rods with new roll pins, KM-308. With F 18/F 18+ transmissions, the shift driver for 5th gear for the gear set brake sliding fork is a longer version. | 
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Install, Connect Press shift driver into 5th gear position, engage 2nd and 3rd gears and bridge with locking pin to end shield (arrow). Insert new bolts with locking compound, 7 Nm/5 lbf. ft. | 
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 Tighten (Torque) Bearing support with pawl to end shield, 7 Nm/5 lbf. ft. Slot in shift rod of 3rd/4th gear must align with pawl. Insert new bolts with locking compound. | 
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Install, Connect Insert 2nd gear with shift sleeve. Drive in 4 closure plugs (arrows) to stop with plastic mallet or soft metal drift.
Important! Bore holes must be oil-tight, if necessary use oversize plugs. | 
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Install, Connect Place end shield assembly on KM-554 (2). Using KM-466-3 (1), press 5th gear (driving) onto gear cluster so that long gear hub faces ball bearing. New retaining ring on gear cluster.
Install, Connect Thrust washer halves on main shaft. Retaining ring on thrust washer halves. Needle bearing on main shaft. Slide 5th gear onto needle bearing. Place synchroniser ring on 5th gear cone. Heat 5th gear synchromesh body to approx. 100 ° C/212 ° F (use thermocolour pencils if available, or suitable temperature gauge) and, using KM-334 (1), press onto main shaft so that synchroniser spring faces gear. New retaining ring onto main shaft. | 
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 Inspect Thread for bearing support for free movement, recut M8 x 1.25 if required.
Tighten (Torque) Bearing support with rocker arm to end shield, 22 Nm/16 lbf. ft. Use new fastening bolts (3 and 4) and insert using locking compound.
Install, Connect Reverse gear thrust washer - note installation position. Install end shield - see operation "Gasket for End Shield, Replace". |
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