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

Remove snap ring (4).
Remove washer (5).
Installation:
Adjust play between snap ring and guide sleeve
to 0 ... 0.09 mm (0 to 0.0035´´).
Always replace snap ring.

Pull off guide sleeve, synchromesh ring, 3rd
gear and needle bearing.

Press 2nd gear, needle bearing, synchromesh
ring, guide sleeve, synchromesh ring, 1st gear,
needle bearing with bearing sleeve and bearing
inner race off of output shaft.
Check condition of all bearings, replacing if
necessary.
Check synchromesh rings (see 23 23 505).


23 23 505

Install needle bearing, 2nd gear, synchromesh
ring and guide sleeve with offset groove facing
1st gear.
Install bearing sleeve and needle bearing in 1st
gear.
Install synchromesh ring.
Press in output shaft.
Important!
Guide in synchromesh ring with tabs in sliding
sleeve.

Heat bearing inner race (7) to approx. 80°C
(175°F) with a hot air blower and install on
output shaft, pressing on with Special Tool
23 1 440 if necessary.

Determine thickness of shim X.
Measure distance (A) from collar of output
shaft to bearing inner race.

Place bearing sleeve for reverse gear in guide
sleeve.
Measure distance (B) from collar of guide sleeve
to bearing sleeve.
Example:
..A ....52.2 mm (2.056´´)
- B ....52.0 mm (2.047´´)
__________________
..X ......0.2 mm (0.008´´) shim thickness

1 Ball bearing
2 Input shaft with 4th gear
3 Turning lock
4 Needle bearing
5 Synchromesh ring
6 Snap ring
7 Washer
8 Thrust part
9 Ball
10 Spring
11 Guide sleeve
12 Sliding sleeve
13 3rd gear
14 Needle bearing
15 Bearing sleeve
16 Output shaft
17 Ball
18 2nd gear
19 1st gear
20 Bearing race
21 Roller bearing
22 Shim X
23 Reverse gear
24 Circlip
25 Bearing sleeve
26 Split needle bearing
27 5th gear
28 Washer
29 Ball bearing
30 Washer
31 Speedometer drive gear
32 Radial oil seal
33 Output flange
34 Collar nut
35 Lockplate
36 Roller bearing
37 4th gear
38 Circlip
39 3rd gear
40 Layshaft
41 Roller bearing
42 5th gear
43 Roller bearing
44 Bolt
45 Washer
46 Washer
47 Thrust washer
48 Needle bearing
49 Reverse gear
50 Bearing shaft
51 Bearing holder