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End Shield, Assemble -
5-Speed Manual Transmission
Press reverse idler gear
shaft, with locking ball in place, into end shield as far as stop.
Insert pins in shift fork
and shift rod of 1st and 2nd gear (P 0062/7) using KM-308/2.
Allow new retaining pin to protrude approx. 2
mm/0.8in.
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Insert main shaft, turbine
shaft, shift fork, shift rod for 1st and 2nd gear and reverse idler gear in
end shield.
End shield bolted to Installer KM-552.
Shift fork groove of reverse idler gear
points upwards (illus P 0063).
Coat bore of reverse idler gear with Extreme
Pressure Lubricant 19 70 300 (6 636 630).
Mount thrust washer on reverse idler gear
shaft.
Secure main shaft and
turbine shaft with snap rings.
Snap rings must seat perfectly in their
grooves.
Use KM-443-B for this.
Use new snap rings.
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P 0062/1: Locking pin for
gear detent
P 0062/2: Shift driver 5th
gear
P 0062/3: Shift fork,
reverse gear
P 0062/4: Shift rod, reverse
gear
P 0062/5: Shift rod, 3rd and
4th gear
P 0062/6: Shift fork, 3rd
and 4th gear
P 0062/7: Shift fork, and
shift rod, 1st and 2nd gear
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Insert shift rod (P 0062/4)
and shift fork (P 0062/3) for reverse gear, shift driver for 5th gear (P
0062/2), shift rod (P 0062/5) and shift fork (P 0062/6) for 3rd and 4th gear,
and locking pin (P 0062/1) for gear detent in end shield.
Use new retaining pins.
Important:
When installing retaining pins, support all
shift rods at top with piece of wood, so that rod guide in end shield is not
overloaded.
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Tighten bridge for locking
pins to end shield - 7 Nm/5.16 lbf. ft.
Coat new bolts (not micro-encapsulated) with
Locking Compound 15 10 177 (90 167 347).
Note:
On F16 and F20 as of MY '90:
shift rod in 3rd/4th gear
are designed 15 mm/0.6 in. longer, due to Teflon bushing in shift driver 5th
gear.
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Tighten bearing support with
pawl to end shield - 30 Nm/22.13 lbf. ft.
Slot in shift rod of 3rd and 4th gear should
correspond to pawl (illus. B 6576 shows F 16).
Coat new bolts (not micro-encapsulated) with
Locking Compound 10 15 177 (90 167 347).
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Drive 4 plugs for detent
pins oil-tight into end shield.
1 long plug (A) for shift rod detent,
3rd and 4th gear.
3 short plugs (arrows) for detent pins.
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Place end shield assembly on
KM-554.
First, press 5th gear
(large) onto gear cluster using KM-466-3.
Long gear hub faces ball bearing.
Secure 5th gear with snap
ring.
Use new snap rings.
Slide 5th gear (small) and
synchronizer ring onto main shaft.
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Then press synchronizer body
for 5th gear onto main shaft using KM-334.
Heat synchronizer assembly to 100 °C/212 °F
(use thermocolour pencils).
Synchronizer spring faces gear.
Use new snap rings.
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Bolt bearing support with
rocker arm to end shield: 22 Nm/16.23 lbf. ft.
Coat new bolts (not
micro-encapsulated) with Locking Compound 15 10 177 (90 167 347).
Bolt competely assembled end
shield (without transmission cover) to main case in vehicle - 15
Nm/11.06 lbf. ft.
Screw fillister head
screw into transmission turbine
shaft and press shaft into gear cluster as far as stop using KM-564.
First carefully insert/slide turbine shaft
into gear cluster by hand.
Secure turbine shaft with
snap ring.
Use new snap ring.
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Bolt transmission cover to end
shield.
Prescribed torque: M 7 x 1.0 = 15
Nm/11.06 lbf. ft.
M 8 x
1.25 = 20 Nm/14.75 lbf. ft.
Fill transmission fluid
through opening of transmission bleed plug.
Important:
If operations are to be
carried out on clutch, transmission cover remains on end shield (except
in F 20 - and all 5-speed manual transmissions as of MY 88 ½).
To pull out and press in
transmission turbine shaft, remove screw cap from transmission.
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