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Main Shaft, Dismantle and Assemble (F18)
Illustration
| 1. |
Main shaft |
| 2. |
4th gear needle bearing |
| 3. |
3rd gear needle bearing |
| 4. |
2nd gear needle bearing |
| 5. |
1st gear needle bearing |
| 6. |
Roller bearing inner ring |
| 7. |
4th gear |
| 8. |
Synchroniser ring |
| 9. |
Shift sleeve |
| 10. |
Synchroniser spring |
| 11. |
Synchromesh body |
| 12. |
Sliding block |
| 13. |
Synchroniser spring |
| 14. |
Thrust washer |
| 15. |
Retaining ring |
| 16. |
Synchroniser ring |
| 17. |
3rd gear |
| 18. |
Thrust washer halves |
| 19. |
Retaining ring |
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Illustration: Main Shaft
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20
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2nd gear
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21
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Inner synchroniser ring
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22
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Intermediate ring
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23
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Outer synchroniser ring
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24
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Shift sleeve
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25
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Synchroniser spring
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26
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Sliding block
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27
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Synchromesh body
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28
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Synchroniser spring
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29
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Thrust washer
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30
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Retaining ring
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31
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Outer synchroniser ring
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32
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Intermediate ring
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33
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Inner synchroniser ring
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34
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1st gear
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35
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Axial needle bearing
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36
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Spacer washer
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37
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Retaining ring
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38
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Ball bearing
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Note: Transmission
remains installed.
 Remove
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Remove gearshift cover (1) – see operation "Gearshift
Cover, Remove and Install and/or Seal (F13/F17/F17+/F18)".
Remove reversing lamps switch (2).
Remove end shield cover (3) – see operation "Gasket for
End Shield Cover, Replace (F13/F17/F17+/F18)".
Remove end shield (4) from transmission – see operation
"Gasket for End Shield, Replace (F13/F17/F17+/F18)".
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Remove
Remove main shaft – see operation "End Shield, Dismantle
and Assemble (F18)".
Disassemble
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Press 1st gear from main shaft with KM-307-B (2) and KM-736
(1).
Remove sleeve (3), ball bearing (4), pressure washer (5), output
shaft (6) and retaining ring (7).
Remove synchroniser rings for 1st gear, consisting of inner
synchroniser ring (8) outer synchroniser ring (10) and intermediate
ring (9).
Remove retaining ring for 1st/2nd gear synchromesh body with
KM-396 (11).
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Disassemble
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Press 1st/2nd gear synchromesh body assembly and 2nd gear (1)
from main shaft – supporting 2nd gear on recesses of press
support plates.
Remove 1st/2nd gear synchromesh body assembly (2) and 2nd gear
synchroniser ring (6) – detach outer synchroniser ring (3),
intermediate ring (4) and inner synchroniser ring (5).
Remove retaining ring (7) for thrust washer and both thrust
washer halves (arrow) from main shaft.
Detach 3rd gear (8).
Detach slotted needle bearing (9) and 3rd gear synchroniser ring
(10). Remove retaining ring for 3rd/4th gear synchromesh body with
KM-396 (11) – remove spacing ring located underneath from
synchromesh body.
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Disassemble
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Press 3rd/4th gear synchromesh body assembly from main shaft
– supporting 4th gear (4) on recesses of press support
plates.
Remove 3rd/4th gear synchromesh body assembly (2) and 4th gear
synchroniser ring (3) from 4th gear. Detached slotted needle
bearing (5) from main shaft.
 Clean
Clean all parts.
Inspect
Check removed parts for damage and wear.
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Note: Coat all parts
with transmission fluid before assembly.
Check parts for wear, signs of scoring, damage; if necessary
replace.
Caution
Always check the gearwheels on the gear cluster for damage to
the gearwheels and replace gear cluster if necessary.
Note: If a
synchromesh body assembly has been completely dismantled then the
following method of procedure shall be observed for assembly.
Assemble
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Insert synchromesh body (3) into shifter collar (2). Insert
slide blocks (1 and 5) with the open end toward synchromesh
body.
Insert synchroniser spring (4); ensure that the correct end of
synchromesh body raises (arrow) for correct installation
position.
If this is not the case, turn synchroniser spring 180° and
reinstall.
Offset end of synchroniser engages in a slide block.
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Assemble
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Push slotted roller bearing (2) onto main shaft, it must audibly
engage on locking. Push double-row, slotted needle bearing (1) onto
main shaft. Position 4th gear synchroniser ring (4) and synchromesh
body assembly (3) on 4th gear (5).
Caution
Side of slider sleeve with groove (arrow) points to 4th
gear.
Assemble
Press 3rd/ 4th gear synchromesh body assembly (7) with
synchroniser ring and 4th gear (6) onto main shaft – ensure
that lugs in synchroniser ring align with grooves in synchromesh
body.
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Assemble
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Place spacer ring on synchromesh body and attach new retaining
ring with KM-396 (3) – ensure that the synchroniser ring is
correctly seated in the groove. Attach 3rd gear synchroniser ring
(2) to synchromesh body assembly and attach slotted needle bearing
(1) to main shaft. Position 3rd gear (5) on main shaft.
Mount both halves of thrust washer (arrows) and retaining ring
(4).
Attach synchroniser rings and synchromesh body assembly (6) onto
2nd gear (10) – outer synchroniser ring (9), intermediate
ring (8) and inner synchroniser ring (7).
Press 1st/2nd gear synchromesh body assembly (12) with 2nd gear
(11) onto main shaft so that lugs of outer synchroniser ring align
with grooves in synchromesh body.
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Assemble
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Insert retaining ring (1) for 1st/2nd gear synchromesh body with
KM-396.
Place 1st gear (2) with synchroniser ring (inner synchroniser
ring, intermediate ring and outer synchroniser ring) on 1st/2nd
gear assembly – ensure that lugs in outer synchroniser ring
align with grooves in synchromesh body.
Attach new retaining ring, output shaft and pressure washer onto
1st gear. Press ball bearing with KM-258 (3) onto main shaft.
Press sleeve (5) onto main shaft with KM-258 (4).
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Inspect
All gears must easily be turned.
Install main shaft – see operation "End Shield with Main
and Drive Shaft, Dismantle and Assemble (F18)".
Install
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Insert end shield (1) into transmission – see operation
"Gasket for End Shield, Replace – F13/F17/F17+/F18".
Install gasket for end shield cover (2) – see operation
"Gasket for End Shield Cover, Replace –
F13/F17/F17+/F18".
Install reversing lamps switch (4) with new seal ring –
tightening torque 20 Nm / 15 lbf. ft.
Install gearshift cover (3) – see operation "Gearshift
Cover, Remove and Install and/or Seal (F13/F17/F17+/F18)".
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Inspect
Check transmission fluid level – see operation
"Transmission Fluid Level, Check and Correct
(F13/F17/F17+/F18)".
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