End Shield, Assemble and Install (F 15/F 17)
 Install, Connect Press reverse idler gear axle with inserted lock ball (arrow) to stop in end shield.
 Important! Note installation position.
Install, Connect Insert bearing seats for main shaft and gear cluster - heat bearing to approx. 80 ° C/176 ° F. Insert main shaft, gear cluster and reverse gear in end shield and secure with KM-444-3. Retaining rings must correctly engage in grooves. Coat bearing and reverse gear bore hole with transmission fluid.
Important! Groove on reverse idler gear shift fork points upwards (arrow downwards). | 
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Install, Connect Insert reverse gear - 1st/2nd gear lock pin (1). Insert shift fork and shift rod and secure with KM-308-2. Allow new roll pin to project by approx. 2 mm. Install shift rod pawl for reverse gear. Insert 1st/2nd gear shift fork and shift rod (2) and secure with pin. Allow new roll pin to project by approx. 2 mm.
Important! To relieve pressure on shift rod guides in end shield, support shift rods with wooden wedge when securing with pin. | 
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Install, Connect Fit 1st/2nd gear shift rod lock (1), drive in using plastic mallet or soft metal drift to stop. Insert 5th gear shift driver (2). Insert 3rd/4th gear shift fork and shift rod and secure with pin.
Important! To prevent stress on shift rod guide, support shift rods with wooden wedge.
Install, Connect Fit 5th gear and 3rd/4th gear shift rod lock (3), drive in to the stop using plastic mallet or soft metal drift. Put shift forks into neutral position. | 
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Install, Connect 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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Install, Connect Heat 5th gear (large) (1) to approx. 100 ° C. Press on gear using KM-466-3 (2).
Important! Long gear hub points to end shield. Install new retaining ring.
Install, Connect Coat both 5th gear needle bearings (3) with transmission fluid and place on main shaft, note correct seating of slotted needle bearing. | 
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Install, Connect Coat seating surfaces of main shaft and synchromesh body with transmission fluid. Slide 5th gear (small) and synchromesh body with sliding sleeve onto main shaft. Fit new retaining ring (1). Compensate end play of shaft (gear cluster). | 
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Install, Connect Insert crosshead shoes into 5th gear shift fork. Fit bearing support with rocker arm (1) on end shield. Insert new bolts with screw locking compound (red).
Important! Ensure that play is not greater than approx. 0.2 mm/0.008 in.
 Tighten (Torque) Bearing support to end shield - 22 Nm / 16 lbf. ft.
Install, Connect Fit friction washer (2) on reverse idler shaft. Adhere friction washer with grease. | 
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Important! Before inserting the transmission unit, check the following components for location and seating.
1 Reverse gear shift fork
4 3rd/4th gear shift fork
6 1st/2nd gear shift fork
Install, Connect Stick on end shield gasket with a little grease. Insert end shield with transmission unit into transmission housing and bolt on.
Tighten (Torque) End shield to transmission housing - 22 Nm / 16 lbf. ft. | 
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Install, Connect Cement gasket for end shield cap with a bit of grease. Place on end shield cap, first install both fit bolts (arrows). Install end shield cap with 4 long bolts (arrows), the fit bolts and the studs for ground strip.
Tighten (Torque) End shield cover to end shield - 15 Nm / 11 lbf. ft. | 
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 Adjust Adjust 5th gear shift fork stop pin. Adjust clearance of 0.2 mm using feeler gauge.
Install, Connect Fit reversing lamp switch (1) and speedometer drive (2) (driven). Adhere gasket for shift cover to transmission housing and install shift cover.
Tighten (Torque)
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Reversing lamps switch to transmission: |
20 Nm / 15 lbf. ft. |
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Shift cover to transmission housing: |
15 Nm / 11 lbf. ft. |
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