End Shield with Main Shaft and Drive Shaft, Disassemble and Reassemble (F 13/F 15/F 17/F 18/F 18+) Notice: Transmission remains installed.
 Remove, Disconnect Remove shift cover (1) - see operation "Shift Cover, Disassemble and Reassemble (F 13/F 15/F 17/F 18/F 18+)". Remove reversing lamps switch (2). Remove end shield cover (3) - see operation "Gasket for End Shield Cover, Replace (F 13/F 15/F 17/F 18/F 18+)". Remove end shield (4) from transmission - see operation "Gasket for End Shield, Replace (F 13/F 15/F 17/F 18/F 18+)". | 
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 Install, Connect Attach end shield to Transmission Bracket 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 fastening bolts are 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 speed gear. | 
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Disassemble Remove retaining ring (1) of 5th speed gear (driving) (2) from drive shaft (3). Place thrust piece (5) for KM-553-A (4) on drive shaft. Remove 5th gear (driving) from drive shaft with KM-553-A. Ensure correct seating of KM-553-A on 5th gear (driving). Remove bearing support (7) with rocker arm (6) from end shield - 2 fastening bolts (arrow).
Important! Micro-encapsulated fastening bolts. If fastening bolts are 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-B (1) from end shield. Remove (3) fastening bolts (4) of bridge for locking pin from end shield.
Important! Micro-encapsulated fastening bolts. If fastening bolts are 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 shift rod guide - support shift rod above with wooden wedge (1).
Disassemble Drive coiled pins (arrows) out of 3rd and 4th gear shift forks (3) and reverse shift fork (6) using drift. Remove shift rods (2), shift forks for 3rd / 4th gear (3) and reverse gear (6) 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-B (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 idler 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 (5) and shift forks (4) with 1st/2nd gear shift rod (3) into end shield and secure with new retaining ring. Use Ring Pliers 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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Assemble Insert locking pin (1) reverse gear 3rd/4th. 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 insert pin with KM-308 (4). Allow new coiled pin to protrude approx. 2 mm/0.08 in (Dimension I). Use KM-308 (4). Notice: To relieve pressure on shift rod guide in end shield, support shift rods with wooden wedge when securing with pin. | 
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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). Notice: To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin.
Assemble Fit four detent pin (5/6/7) and drive to stop with plastic mallet 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 screw locking compound (red). Position bridge (2) for locking pin on end shield and lightly tighten with 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. Cover new fastening bolts (arrow) with screw locking compound (red). Attach bearing bracket (4) with pawl (3) to end shield (2 fastening bolts) - tightening torque 9 Nm / 7 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. Install 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 running 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 shift fork (4). Coat new fastening bolts with screw locking compound (red). Attach bearing bracket with cam follower 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 idler axle. Cement friction washer with 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 gear 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 (F 13/F 15/F 17/F 18/F 18+)". Install gasket for end shield cover (2) - see operation "Gasket for End Shield Cover, Replace (F 13/F 15/F 17/F 18/F 18+)". Install reversing lamps switch (4) with new seal ring - tightening torque 20 Nm / 15 lbf. ft. Install shift cover (3) - see operation "Shift Cover, Disassemble and Reassemble (F 13/F 15/F 17/F 18/F 18+)".
Inspect Check transmission fluid level - see operation "Transmission Fluid Level, Check and Correct (F 13/F 15/F 17/F 18/F 18+)". | 
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