| Disassembly and Assembly of Subassemblies Special Tool(s) | | Installer, bearing outer and oil seal 204-016 | | | Installer, Front Wheel Hub Bearing Race/Oil Seal 204-050 | | | Adapter for 205-071 (Thrust Pad) 205-071-01 | | | Remover, Bearing (Main Tool) 205-295 | | | Installer, Extension Housing Bushing/Oil Seal 308-046 | | | Collet for 205-295 308-196 | | | Collet for 205-295 308-197 | | | Installer, Output Drive Flange Oil Seal 308-604/2 | | | -
Clamp the output shaft in the vice. | 2. Disassemble the components in the order indicated in the following illustration(s) and table(s). 5 - Needle roller bearing - 4th gear wheel 6 - Inner synchronizer ring - 4th gear 7 - Synchronizer cone - 4th gear 8 - Outer synchronizer ring - 4th gear 11 - Outer synchronizer ring - 3rd gear 12 - Synchronizer cone - 3rd gear 13 - Inner synchronizer ring - 3rd gear 15 - Needle roller bearing - 3rd gear wheel 18 - Needle roller bearing - 2nd gear wheel 19 - Inner synchronizer ring - 2nd gear 20 - Synchronizer cone - 2nd gear 21 - Outer synchronizer ring - 2nd gear 24 - Outer synchronizer ring - 1st gear 25 - Synchronizer cone - 1st gear 26 - Inner synchronizer ring - 1st gear 28 - Needle roller bearing - 1st gear wheel 29 - Output shaft - 1st - 4th gear 3. To assemble, reverse the disassembly procedure. Disassembly Details Item 1 : Output shaft clutch-side taper roller bearing | | -
Remove the clutch-side taper roller bearing from the output shaft using the special tool. | Item 2 : Retaining bolt for output shaft transmission-side taper roller bearing | | -
Remove the retaining bolt for the transmission-side taper roller bearing from the output shaft. - Heat the transmission-side taper roller bearing retaining bolt to approx. 90°C using a hot air gun.
| Item 3 : Output shaft transmission-side taper roller bearing | | -
NOTE:Use a suitable washer as a thrust element. Remove the transmission-side taper roller bearing from the output shaft using the special tool. | Item 10 : Synchronizer assembly - 3rd and 4th gear | | -
Manually remove the 3rd and 4th gear synchronizer assembly together with the 3rd gear wheel. | | | -
NOTE:Mark the position of the sliding sleeve on the synchronizer hub for installation. Components are paired. Disassemble the 3rd and 4th gear synchronizer assembly. - Sliding sleeve
- Blocker bars
- Synchronizer hub
| Item 16 : Snap rings and retainer | | -
Remove the snap rings. - Remove the snap rings from the output shaft.
| Item 23 : Synchronizer assembly - 1st and 2nd gear | | -
Manually remove the 1st and 2nd gear synchronizer assembly together with the 1st gear wheel. | | | -
NOTE:Mark the position of the sliding sleeve on the synchronizer hub for installation. Components are paired. Disassemble the 1st and 2nd gear synchronizer assembly. - Sliding sleeve
- Blocker bars
- Synchronizer hub
| Item 30 : Oil ring | | -
NOTE:This step is only necessary if the oil ring is damaged. Remove the oil ring using an internal extractor. | Assembly Details Item 30 : Oil ring NOTE:Coat all running surfaces with clean transmission fluid before assembly. | | -
CAUTION:Ensure that the specified installation depth is achieved. NOTE:New output shafts are supplied without an oil ring. NOTE:The oil ring and shaft bore must be clean and free of oil or grease. NOTE:The open side of the oil ring must face outwards. Install oil ring to specified installation depth (X = 7.0 mm - 8.5 mm) using special tool. | Item 23 : Synchronizer assembly - 1st and 2nd gear | | -
NOTE:Ensure that the marks align with one another. Assemble 1st and 2nd gear synchronizer assembly. - Synchronizer hub
- Blocker bars
- Sliding sleeve
| | | -
NOTE:The large collar must face upwards. Install 1st and 2nd gear synchronizer assembly using the special tool. | Item 16 : Snap rings and retainer | | -
NOTE:The inner collar of the retainer ring must face upwards. Attach the snap rings. - Insert the snap rings in the output shaft.
| Item 10 : Synchronizer assembly - 3rd and 4th gear | | -
NOTE:Ensure that the marks align with one another. Assemble the 3rd and 4th gear synchronizer assembly. - Synchronizer hub
- Blocker bars
- Sliding sleeve
| | | -
NOTE:The large collar must face downwards. Install the 3rd and 4th gear synchronizer assembly using the special tool. | Item 3 : Output shaft transmission-side taper roller bearing | | -
NOTE:Install a new output shaft transmission-side taper roller bearing. NOTE:Do not oil taper roller bearings. Press on the output shaft transmission-side taper roller bearing using the special tool. | Item 2 : Retaining bolt for output shaft transmission-side taper roller bearing | | -
NOTE:Install a new retaining bolt for the transmission-side taper roller bearing. NOTE:The retaining bolt and thread must be clean and free of oil or grease. Install the retaining bolt for the transmission-side taper roller bearing in the output shaft. | Item 1 : Output shaft clutch-side taper roller bearing | | -
NOTE:Install a new output shaft clutch-side taper roller bearing. NOTE:Do not oil taper roller bearings. Press on the output shaft clutch-side taper roller bearing using the special tool. | | 
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