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End Shield with Main Shaft and Drive Shaft, Remove and
Disassemble
F 10/5, F 13/5 Manual Transmission
Shift transmission (arrow) into 2nd gear (rear shift fork).
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Unbolt end shield from transmission housing.
Pull end shield, together with main shaft and drive shaft,
from transmission housing.
Note magnet which is released.
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Fasten end shield to transmission stand using
KM - 552 in conjunction with KM - 113 - 2.
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Unbolt bearing support with rocker arm from end shield
(arrows) and remove.
May be difficult to move, avoid damage.
If necessary, heat end shield with hot air dryer.
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Pull synchromesh body of 5th gear from main shaft, using
KM - 161 - A together with Hook
KM - 161 - 2 or KM - 533 - A.
While doing this, simultaneously engage two gears (e.g. 3rd and
reverse gear).
Remove retaining ring in front of synchromesh body beforehand.
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Remove 5th gear (driven), needle bearing for 5th gear,
retaining ring for thrust washers, and both halves of the thrust washers from
the main shaft.
The needle bearing has slits and can be slightly spread
open.
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Pull 5th gear (driving) from gear cluster, using
KM - 553.
Place pressure piece under gear cluster.
Remove retaining ring in front of gear wheel beforehand.
Important:
The pressure piece must not sit on the drive shaft in the gear
cluster.
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Unbolt bearing support with pawl from end shield.
If microencapsulated bolts are difficult to move, heat end
shield with hot air dryer to approx 80 °C/176 °F.
(Use thermocolour pencil or suitable temperature gauge).
To replace the pawl, press pin out of bearing support.
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Remove 4 plugs for shift lock from end shield using
KM - 328- B.
Up to MY '90 (P 0066):
Remove pressure springs and stop pins from bore holes.
Also use KM - 457 - A.
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As of MY '91:
Closure sleeves, pressure springs and stop balls cannot be
disassembled.
Also use KM-727.
Note:
Plugs (up to MY '90) and (as of MY '91) are not interchangeable,
as the relevant shift rods have different profiles.
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Unscrew and remove bridge for locking pins from the end
shield.
If microencapsulated bolts are difficult to move, heat end
shield with hot air dryer to approx. 80 °C/176 °F.
(Use thermocolour pencils or suitable temperature gauge).
In doing this, engage 2nd and (with shift driver) 5th gear.
When 3rd gear is subsequently engaged, bridge is pushed out.
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Use suitable drift to drive retaining pins out of 3rd and
4th gear as well as reverse gear shift fork.
Important:
When removing the retaining pins, support all shift rods on top
using a piece of wood so as not to overload the rod guide in the end shield.
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Remove shift rods and shift forks of 3rd and 4th gear, as
well as reverse gear, from the end shield.
Pull shift driver of 5th gear out of end shield.
Shift sleeve in neutral.
Note:
As of approx. MY '91:
5th gear shift driver is equipped with Teflon bushings for
guiding 3rd and 4th gear shift rods.
Therefore, this shift rod is approx. 15 mm/0.6 in.
longer.
Both parts are not interchangeable with previous
versions.
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Remove locking pin for locking device from end shield bore
hole (arrow).
Illustration P 0076 shows operation for F 10/4
manual transmission.
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To remove the main shaft and drive shaft together with
reverse idler gear, shift fork and shift rod for 1st and 2nd gears from the
end shield, remove the retaining rings for main shaft and drive shaft using
KM - 443 - A (2).
To aid disassembly, the retaining ring for main shaft can be
held with an assembly aid plate (1).
Tool KM - 443 - B contains: angle nose
pliers (2) and assembly aid plate (1).
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Assembly aid plate can be constructed in own workshop
according to dimensions in illus. C 1084.
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When replacing end shield or reverse idler gear shaft:
Remove reverse idler gear shaft from end shield.
Clamp the shaft between protective jaws in a vise.
Drive off end shield carefully with a brass drift.
Note locking ball.
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