End Shield, Disassemble and Assemble (F 13) Illustration
4 1st/2nd gear shift fork
9 3rd/4th gear shift fork
10 3rd/4th gear shift rod
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Illustration (Continued)
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11 |
5th gear shift driver |
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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 |
Crosshead shoe |
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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 |
Fastening bolt M8 |
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21 |
Fastening bolt M7 |
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22 |
Fastening 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 |
Synchromesh body 5th gear |
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27 |
Synchroniser spring |
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28 |
Shifter collar 5th gear |
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29 |
Synchroniser ring 5th gear |
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Illustration (Continued)
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30 |
Gear 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 |
Gear 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 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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Notice: Transmission remains installed.
 Remove, Disconnect Remove cover (1) for shift mechanism - see operation "Cover for Shift Mechanism, Remove and Install and / or Seal". Remove reversing lamps switch (2). Remove end shield cover (3) - see operation "Gasket for End Shield Cover, Replace". Remove end shield (4) from transmission - see operation "Gasket for End Shield, Replace". | 
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 Install, Connect Attach end shield to KM-552 (2). Attach KM-552 to KM-113-2 (1).
Remove, Disconnect Remove bearing support (6) with rocker arm (7) from end shield (2 fastening bolts).
 Important! Micro-encapsulated fastening bolts. If stiff, heat end shield with hot-air dryer to approx. 80 ° C.
 Disassemble Remove retaining ring (8) from synchromesh body. Remove 5th speed gear (4) synchromesh body with 5th speed gear (5) (small) from main shaft, if stiff use KM-161-B (3). Remove both needle cages for 5th gearwheel. | 
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Disassemble Remove retaining ring (1) of 5th gear wheel (driving) (2) from drive shaft (3). Place thrust piece (5) for KM-553-A (4) onto drive shaft. Remove gearwheel for 5th gear (driving) from drive shaft with KM-553-A. Ensure correct seating of KM-553-A at gearwheel for 5th gear (driving). Remove bearing support (7) with rocker arm (6) from end shield - 2 fastening bolts (arrow).
Important! Micro-encapsulated fastening bolts. If stiff, heat end shield with hot-air dryer to approx. 80 ° C. | 
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Disassemble Remove stop plugs (arrows) with KM-727-B (2) and KM-328 (1) from end shield. Remove (3) fastening bolts (4) of bridge for locking pin from end shield.
Important! Micro-encapsulated fastening bolts. If stiff, heat end shield with hot-air dryer to approx. 80 ° C.
Disassemble Engage 2nd and 5th gears (with shift driver). If 3rd gear is now engaged, the bridge will be pushed out. | 
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Notice: Relieve pressure on shifter rod guides - for this, support shifter rods above with wood (1).
Disassemble Drive coiled pins (arrows) out of 3rd / 4th gear shift fork (3) and reverse shift fork (6) using KM-308. Remove 3rd, 4th (3) and reverse gear (6) shifter rods (2) and shift forks from end shield. Remove 5th gear shift driver (4) from end shield. Remove locking pin (5) for catch from end shield bore holes. | 
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Disassemble Remove retaining rings for main shaft (2) and drive shaft (5) with KM-443 (6) from grooves of end shield. As assembly aid, tension retaining ring for main shaft with installation plate (1). Remove main shaft (2) from end shield. Remove drive shaft (5) from end shield. Remove reverse idler (8) from end shield. Remove shift fork (4) and shift rod 1st and 2nd (3) gear from end shield. Clamp reverse gear (7) in vice with protective jaws. Carefully knock off end shield with brass punch.
Important! Note that retaining ball is released. | 
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 Clean Clean all parts and sealing surfaces.
 Inspect Check parts for wear, signs of scoring, damage; if necessary replace. Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid.
Install, Connect Press reverse gear axle with inserted lock ball (arrow) to start in end shield.
Important! Note installation position. | 
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 Assemble Coat bearing and reverse bore hole with transmission fluid. Insert main shaft (2), drive shaft (1), reverse gear wheel (5) and shift fork (4) with 1st/2nd gear shift rod (3) into end shield and secure with new retaining ring, for this insert retaining rings with KM-443-B. Notice: Retaining rings must engage correctly in grooves. Shift fork groove (arrow) for reverse idler gear (5) points upwards. | 
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Notice: To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin.
Assemble Insert locking pin (1) reverse gear 3rd/4th. Allow new coiled pin to protrude approx. 2 mm/0.08 in (Dimension I). Insert shift fork (5) and reverse gear shift rod (6) and secure with Pin KM-308 (4). Insert shift fork (3) and shift rod (2) for 1st/2nd gear and pin with KM-308 (4). | 
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Notice: To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin.
Assemble Insert 5th speed gear (4) shift driver. Insert shift fork (2) and shift rod for 3rd/4th gear (1) and Pin KM-308 (3).
Assemble Fit four detent pins (5/6/7) and drive to stop with plastic hammer or soft metal drift. Bring shift fork into neutral speed position. | 
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Assemble Engage 2nd/3rd/5th gear. Coat new fastening bolts (1) with locking compound. Position bridge (2) for locking pin on end shield and lightly tighten with (3) fastening bolts. Switch 1st/2nd gear shift fork to neutral. Attach bridge fastening bolts - 7 Nm / 5 lbf. ft. Bring shift fork into neutral speed position. Coat new fastening bolts (arrow) with locking compound. Attach bearing bracket (4) with pawl (3) to end shield (2 fastening bolts) - tightening torque 7 Nm / 5 lbf. ft. | 
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Assemble Remove end shield with KM-552 from KM-113-2. Insert end shield with main and drive shaft into KM-554 (2). Press on gearwheel for 5th gear (driving) with KM-514 (1).
Important! Long gear hub points to end shield. Fit new retaining ring (3).
Assemble Attach end shield with KM-552 to KM-113-2. Coat both needle bearings (5) for 5th speed gear (4) with transmission fluid and place on main shaft. Ensure correct seating of slotted needle bearings. | 
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Assemble Coat seating surfaces of main shaft and synchromesh body with transmission fluid. Slide 5th speed gear (2) and synchromesh body (1) onto main shaft and secure with new retaining ring (3). Insert crosshead shoe (arrow) in 5th gear control fork (4). Coat new fastening bolts with locking compound. Attach bearing bracket with rocker arm to end shield (2 fastening bolts) - tightening torque 22 Nm / 16 lbf. ft. | 
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Install, Connect Fit friction washer (arrow) on reverse gear axle. Adhere friction washer with high-pressure grease.
Important! Before installation of transmission unit check following items for position and seating.
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1 |
3rd/4th gear shift rod |
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2 |
3rd/4th gear shift fork |
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3 |
5th gear shift driver |
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4 |
1st/2nd gear shift rod |
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5 |
1st/2nd gear shift fork |
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6 |
Lock pin for gear stop |
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7 |
Reverse shift fork |
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8 |
Reverse gear shift rod |
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Install, Connect Install end shield (1) in transmission - see operation "Gasket for End Shield, Replace". Install gasket for end shield cover (2) - see operation "Gasket for End Shield Cover, Replace". Install reversing lamps switch (4) with new seal ring - tightening torque 20 Nm / 15 lbf. ft. Install cover (3) for shift mechanism - see operation "Cover for Shift Mechanism, Remove and Install and / or Seal".
Inspect Check transmission fluid level - see operation "Transmission Fluid Level, Check". | 
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