Vehicles after change point in 1982
REPLACING OUTPUT SHAFT
- Otuput Shaft Removed -
Pull off input shaft (1), synchromesh ring (2)
and needle bearing (3).

Lift out circlip (4).
Take off shim (5).

Press off the 3rd gear wheel with guide and
sliding sleeves with Special Tool 23 1 490.
Take off the needle bearing.
Pressing-off force*.


* See Specificatiions

Lift out circlip (6).
Installation:
Replace circlip.

Press 2nd gear wheel, guide sleeve and 1st gear
wheel off of the output shaft.

Pull collar (7) off of the output shaft with
Special Tool 00 7 500.

Take off shim (X) and roller bearing (8).

Important!
Determine the thickness of shim (X) and
circlip (6) before installation of the gear
wheel set.
Parts can supply shims in thicknesses from
0.3 to 0.5 mm (0.012 to 0.020´´) and circlips
from 1.7 to 1.9 mm (0.067 to 0.075´´).

Determine thickness of shim X.
Measure distance (A) from collar of 3rd/4th
gear guide sleeve to bearing surface of 1st
gear collar; for example:
128.3 mm (5.051´´).

Assemble the 1st gear collar, 1st/2nd gear
guide sleeve and 2nd gear collar.
Measure distance (B); for example:
Example:
..A = 128.3 mm (5.051´´)
- B = 93.1 mm (3.665´´)
___________________
..........35.2 mm (1.386´´)
- C = 34.7 mm (1.366´´)
___________________
..X = 0.5 mm /0.020´´) shim thickness

Determine thickness of circlip (6).
Install old circlip in groove.
Measure distance (D) from bearing surface of
1st gesr collar to lower edge of the circlip.
This requires that the circlip is pressed tight
in the groove.
For example:
93.6 mm (3.685´´).

Measure thickness (E) of old circlip.
For example: 1.9 mm (0.075´´).
Example:
.. D = 93.4 mm (3.677´´´)
+ E = 1.9 mm (0.075´´)
___________________
.. F = 95.3 mm (3.752´´)

Example:
.. B = 93.1 mm (3.665´´)
+ X = 0.5 mm (0.020´´)
___________________
.. G = 93.6 mm (3.685´´)
.. F = 95.3 mm (3.752´´)
- G = 93.6 mm (3.685´´)
__________________
.. E = 1.7 mm (0.067´´) circlip thickness

Install roller bearing (9) with the small
diameter end of the plastic cage facing the
collar.
Install shim X of determined thickness.

Heat collar (7) to about 80°C (175°F) with
a hot air blower.
Install collar.

Install the split needle bearing, 1st gear wheel
and synchromesh ring on the output shaft.

Install 1st/2rd gear guide sleeve with the
identification groove facing the 2nd gear
wheel.
Press on guide sleeve to fit tight with Special
Tool 23 1 290.
Pressing-on force*.
Important!
Make sure tabs on synchromesh ring are
aligned with openings in guide sleeve while
pressing on.


* See Specifications

Install synchromesh ring, needle bearing and
2nd gear wheel.

Heat collar (10) to about 80°C (175°F) with
a hot air blower.
Install collar on the output shaft, pressing on
to fit tight with Special Tool 23 1 290 if
necessary.
Turn the 2nd gear wheel to prevent seizure of
the needle bearing.

Install circlip (6) of determined thickness.

Install needle bearing, 3rd gear wheel and
synchromesh ring.
Install 3rd/4th gear guide sleeve with the
identification groove facing the 4th gear
wheel and press on with Special Tool
23 1 440.
Important!
Tabs on synchromesh ring must be aligned
with openings in guide sleeve.

GEAR WHEEL SET WITH BEARINGS
1 Circlip
2 Shim
3 Shim
4 Bearing
5 Input shaft with 4th gear wheel
6 Synchromesh ring
7 Needle bearing
8 Circlip
9 Shim
10 Guide sleeve
11 Spring
12 Ball
13 Drive dog
14 Operating sleeve
15 3rd gear wheel
16 Needle bearing
17 Circlip
18 Shim
19 2nd gear wheel
20 Needle bearing
21 Operating sleeve
22 Guide sleeve
23 1st gear wheel
24 Needle bearing
25 Shim
26 Shim
27 Output shaft

GEAR WHEEL SET WITH BEARINGS
27 Output shaft
28 Ball
29 Needle bearing
30 Reverse gear wheel
31 Synchromesh ring
32 Operating sleeve
33 Guide sleeve
34 Circlip
35 Needle bearing
36 5th gear wheel
37 Thrust washer
38 Ball bearing
39 Output flange
40 Collar nut
41 Lockplate
42 Bolt
43 Washer
44 Shim
45 Ball bearing
46 4th gear wheel
47 Circlip
48 3rd gear wheel
49 Layshaft
50 Roller bearing
51 5th gear wheel
52 Roller bearing
53 Needle bearing
54 Reverse gear
55 Shaft
56 Spring washer
57 Bolt