Main Shaft, Disassemble and Assemble (F 13) Main Shaft, Dismantle If the gears are damaged, always also replace the gear cluster. Press off ball bearing, retaining ring (long leg), spacer washer, axial needle bearing and 1st gear using appropriate drift. Remove needle bearing for 1st gear from main shaft. Remove 3 synchroniser rings (1st gear), shift sleeve and sliders. Retaining ring for 1st/2nd gear synchromesh body. Press off 1st/2nd gear synchromesh body, 3 synchroniser rings (2nd gear), and 2nd gear with suitable Drift KM-307-B.
 Remove, Disconnect Remove retaining ring in front of drive gear (driving) from main shaft. Press off drive gear (driving) from main shaft with KM-307-B and suitable drift.
 Important! Always replace drive gears (driving and driven) in pairs | 
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Remove, Disconnect Place KM-479-A in groove of 4th gear. Press off spacer washer and 4th gear. Remove synchroniser ring (4th speed gear), shift sleeve and slider. Remove retaining ring for 3rd/4th gear synchromesh body from main shaft. Press off 3rd/4th gear synchromesh body and 3rd gear with suitable drift. | 
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 Clean Clean all parts.
 Inspect Immerse all parts in transmission fluid before installation. Check removed parts for damage and wear.
Main Shaft, Assemble Lubricate all bearing bore holes and seating surfaces with transmission fluid before installation. All transmissions have 3-cone synchronisation for 1st and 2nd gears:
2 Inner synchroniser rings
4 Outer synchroniser rings
8 Synchroniser hub (carrier)
 Assemble Assemble synchromesh body for 1st/2nd gear and 3rd/4th gear. Suspend synchroniser springs oppositely directed with their hooks in the slider, so that the free end of the spring lies apart from the synchromesh body. Insert slider in flat centre tooth of the shift sleeve. | 
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 Install, Connect Slide 3rd speed gear from drive gear side onto main shaft so that the cone points in direction of drive gear. Place synchroniser ring onto 3rd gear cone. Heat 3rd/4th gear synchromesh body assembly to 100 ° C/212 ° F and with KM-277 press onto main shaft. Install new retaining ring in front of 3rd/4th gear synchromesh body. Slide synchroniser ring and 4th gear onto main shaft. Heat spacer washer and drive gear (driving) to 100 ° C/212 ° F. Place spacer washer onto main shaft with grooves pointing towards 4th gear. Press drive gear onto main shaft so that collar of spacer washer faces upwards - use KM-311/2. Insert new retaining ring in front of drive gear. Always replace drive gears in pairs. | 
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Install, Connect Slide gear wheel 2. gear onto main shaft. Seat inner synchromesh ring onto conus of wheel gear. Seat intermediate ring onto inner ring in such a way that lugs are seated inside grooves of gear wheel. Seat outer synchromesh ring onto intermediate ring in such a way, that grooves are seated on lugs of inner synchromesh ring. Heat synchromesh body 1/2 gear to approx. 100 ° C and, by using KM-277, press onto main shaft in such a way, that lugs of the outer synchromesh ring are aligned with grooves of synchromesh body. Gear fork groove points to ball bearing seat. Install new retaining ring in front of 1/2 gear synchromesh body. Place outer synchroniser ring with lugs in grooves of synchromesh body. Place intermediate ring on outer synchroniser ring. Place inner synchroniser ring on intermediate ring with lugs in grooves of outer synchroniser rings. Place 1st gear needle bearing on main shaft. Slide 1st gear onto needle bearing with grooves on lugs of intermediate ring. Place thrust needle bearing (arrow) on 1st gear. Heat spacing washer to approx. 100 ° C/212 ° F and place on needle bearing. | 
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Install, Connect Place new retaining ring with long legs for main shaft to end shield on 1st gear. Press ball bearing with KM-334 onto main shaft.
Inspect All gears must be easy to turn. | 
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