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Drive Pinions, Both (Driving and Driven), Replace
These operations are to be carried out with transmission
housing installed.
See "Manual Transmission and Differential,
Overhaul" and "Synchronizer Rings, Replace" for additional
information.
Drive Pinion (Driven), Remove
Raise vehicle. Remove both front wheels.
Unscrew differential cover from transmission housing (fluid
will drain out.)
Unbolt swivel joint from both sides of steering knuckle.
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Drive both shafts out of transmission case using
KM - 460 - A - 2 (left side, modified tool)
and KM - 460 - 1 (right side).
Important:
The chamfered side of the tool must always face the transmission.
Suspend drive shafts immediately. Do not allow to sag.
Mark bearing ring position in relation to transmission casing
on the ring and the case.
Check for axial play in the tapered roller bearing.
Turn bearing ring out of transmission casing using
KM - 447 and remove differential.
Clamp differential housing in vice with
KM - 458 - A.
Unbolt ring gear from differential housing and knock off with
brass drift.
Drive Gear (Driven), Install
Tightly bolt new drive gear to differential housing -
important attaching part, observe prescribed torque 85 Nm/63 lbf. ft.
Important:
Heat drive gear to approx. 80 °C/176 °F (use
thermocolour pensils or suitable temperature gauge).
Insert differential in differential housing.
Bolt in bearing ring with KM - 447 into housing.
In doing this, note adjusting instruction for diffential tapered
roller bearing under f.
Tightly bolt cover for differential at differential housing -
30 Nm/22 lbf. ft. on sheet-metal version, 18 Nm/13 lbf. ft. on fight
alloy version.
Drive both drive shafts into transmission housing. Then use
suitable drift to drive them in until the retaining ring snaps in place.
First insert new retaining ring into axle shaft.
Important:
Do not overstress retaining ring.
After the retaining ring snaps into place, check that it is
seated properly by pulling on the outer diameter of the joint.
Important:
Seating of the axle shaft cannot be checked by pulling on the
shaft.
Fasten swivel joint with bolt and nut to steering knuckle -
important mounting part.
Observe prescribed torque - 30 Nm/22 lbf. ft.
Tighten wheel bolts alternating crosswise and observe
prescribed torque - 110 Nm/81 lbf. ft.
Fill transmission fluid.
Drive Pinion (Driving), Remove
Remove universal joint pin from shift linkage. Separate
linkage from transmission.
Unbolt reversing lamps switch.
Unscrew gearshift control cover from transmission casing and
remove. Shift transmission into 2nd gear.
Unscrew cap or end shield cover from end shield.
Unscrew fillister head screw from drive shaft (remove
retaining ring).
Pull out transmission drive shaft using
KM - 556 - 1 - A (was
KM - 449 - 1 in conjunction with Kukko Support
22 - 1).
Do not actuate clutch beyond this point.
Unbolt end shield from transmission casing.
Pull end shield with main shaft and drive shaft out of
transmission casing and mount on KM-552.
Drive 3 plugs for shift detent out of end shield using
KM - 457 - A (up to MY '90) or
KM - 727 (as of MY '91) in conjunction with
KM - 328 - B.
For 5-speed transmission: 4 plugs.
Use drift to drive retaining pins out of 3rd and 4th gear
shift fork and reverse gear shift fork.
Remove shift rods and 3rd and 4th gear shift forks and
reverse gear from end shield.
For 5-speed transmission: remove gears and actuators of 5th gear.
Remove from the end shield both retaining rings fastening the
main shaft and drive shaft.
Withdraw main shaft, drive shaft, reverse idler gear and
shift fork with 1st and 2nd shift rod from end shield.
Use KM - 307 - A and suitable drift to
remove drive pinion from the main shaft (remove retaining ring).
If necessary, pull needle sleeve with roller bushing with
KM - 556 - A out of transmission casing and press in new
part.
Drive Gear (Driving), Install
Press new drive gear onto main shaft using
KM - 311 - 2 and secure with retaining ring.
Important:
Preheat drive gear to approx. 100 °C/212 °F (use
thermocolour pencils or suitable temperature gauge).
Insert main shaft, drive shaft, 1st and 2nd gear shift fork
and shift rod as well as reverse idler gear into end shield.
Secure main shaft and drive shaft with retaining ring.
For 5-speed transmission: remove gears and actuators of 5th gear.
Use KM - 308 (SW - 203) to insert
retaining pins into 3rd and 4th gear shift forks and shift rod as well as into
reverse gear.
As of MY '91: 3rd and 4th gear shift rod is
15 mm/.59 in. longer (only on S-speed transmission)
Insert 3 detent pins with pressure springs and drive in
plugs. As of MY '91: Changed version of closure plug - see operation
"Manual Transmission and Differential, Overhaul / End Shield, Assemble and
Install"
Use shifting sleeve to shift into 2nd gear.
Carefully insert the completely assembled end shield into
transmission casing and tighten to prescribed torque - 22 Nm/16 lbf. ft.
Screw fillister head screw into transmission drive
shaft and use KM - 564 to press drive shaft up to the stop on the
gear cluster.
Secure drive shaft with retaining ring.
Install the screw cap in bearing cover and seal against oil
with Sealing Compound 15 03 166 (90 094 714) or PVC
tape 50 Nm/37 lbf. ft., or, for 5-speed transmission up to
MY '88 ½, 30 Nm/23 lbf. ft.
As of MY '88 ½, tighten end shield cover to end
shield - M 7: 15 Nm/11 lbf. ft., M 8: 20 Nm/15
lbf. ft.
Bolt gearshift control cover to transmission case. Observe
prescribed torque - 15 Nm/11 lbf. ft.
Measurement required, see operation "Shift Cover,
Assemble and Install".
Belt on reversing lamps switch. Observe prescribed torque -
20 Nm/15 lbf. ft.
Connect cardan joint to gearshift linkage with pin and secure
it with clamp - up to MY '90.
Connect cardan joint to gearshift linkage with new hollow pin
- as of MY '91.
On all models:
Coat pin of cardan joint with Silicone Grease
19 70 206 (90 167 353).
