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End Shield, Assemble and Install
F 10/5, F 13/5 manual transmission:
Press shaft of reverse idler gear with stop ball as far as
stop in end shield.
Illustration A 8184 shows operation for 4-speed
transmission.
Insert locking pins for gear locking (component 1 in
following assembly diagram D 0226) into end shield bore hole.
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Use KM - 308/2 to install pin of shift fork and
rod of 1st and 2nd gear (D 0226/7).
Allow new retaining pin to protrude approx. 2 mm/.08 in.
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Guide main shaft, drive shaft, shift fork and shift rod, 1st
and 2nd gears, as well as reverse idler gear into end shield.
Fasten end shield to KM-552.
In reverse idler gears as of approx. MY '88, the
slanted fluid bore hole is no longer present. This version is inter
changeable with the previous one.
Shift fork groove in reverse idler gear faces upward
(arrow).
Apply Transmission Fluid
19 40 750 (90 001 777) to bore in reverse idler
gear.
Place thrust washer on reverse idler gear shaft and adhere
with Antifriction Bearing Grease
19 41 574 (90 001 812).
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Secure main shaft and drive shaft with retaining rings.
The retaining rings must engage correctly in the bearing
groove.
For this, use KM - 443 - A (2) and
installation tool (1) or KM - 443 - B.
Use new retaining rings.
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1: Locking pin for gear locking
2: Shift driver, 5th gear
3: Shift fork, reverse gear
4: Shift rod, reverse gear
5: Shift rod, 3rd/4th gear
6: Shift fork, 3rd/4th gear
7: Shift fork and shift rod, 1st/2nd gear
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Insert and pin shift rod - (D 0226/4) and shift fork,
reverse gear, (D 0226/3), shift driver, 5th gear (D 0226/2) as well
as shift rod (D 0226/5) and shift fork (D 0226/6), 3rd/4th gear in
end shield, KM - 308.
Use new pins.
Rod guides must not be under stress; support with wooden
block.
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Bolt on bridge for locking pin on end shield
(arrows) - 7 Nm/5 lbf. ft.
Coat new bolts with Locking Compound
15 10 177 (90 167 347).
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Bolt on bearing support with pawl on end shield 9 Nm/7
lbf. ft.
Slit in shift rod, 3rd and 4th gears, must match pawl (arrow).
Coat new bolts with Locking Compound
15 10 177 (90 167 347).
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Drive four plugs for locking pins oil-tight into end shield.
UP to MY '90:
Insert locking pins and pressure springs into end shield
bore holes.
One long plug (A) for shift rod locking device, 3rd and 4th
gears.
3 short plugs (arrows).
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As of MY '91:
Drive in plugs with pressure springs and stop balls as far
as stop with plastic mallet or soft metal drift.
One long plug (1).
Three short plugs (2).
All models:
Bore holes must be oil-tight, if necessary use oversize
plugs.
Insert 2nd gear with shift sleeve.
Note:
The two versions are not interchangeable with one
another.
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Place end shield assembly on KM - 554. K
First, press 5th gear (driving) onto gear cluster with
KM - 466 - 3.
Long gear hub faces ball bearing.
Use new retaining ring.
Push 5th gear (driven) 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 body assembly to approx.
100 °C/212 °F (use thermocolour pencils or suitable
temperature gauge).
Synchronizer spring faces gear.
Use new retaining rings.
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Bolt bearing block with drag lever to end shield -
22 Nm/16 lbf. ft.
Coat new bolts with Locking Compound
15 10 177 (90 167 347).
Bolt completely assembled end shield (without
transmission cover) to transmission housing - 22 Nm/16 lbf. ft.
Insert magnet.
Stick gasket to transmission housing with Antifriction
Bearing Grease 19 41 574 (90 001 812).
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