DISASSEMBLING/ASSEMBLING SYNCHRONIZATION
- Transmission Removed -
Remove input and output shafts 23 21 503.
Disassemble output shaft (see 23 21 554).
All synchromesh rings are identical and coated
with molybdenum on inside surface.
Synchromesh rings must be replaced when distance
between synchromesh rind and clutch body is less
than 1.0 mm (0.040´´).
Measure in area of stops.
This distance is 1.0 to 1.3 mm (0.040 to 0.051´´)
for new synchromesh rings.


Siehe auch 23 21 503
Siehe auch 23 21 554
63023077 - click to zoom
 
Check synchronization.
Disassemble synchronizer.
Spring (1), thrust pad (2) and ball (3).

63023078 - click to zoom
 
Installation: Install all springs, thrust pads and
balls.
Important: Curved surfaces of thrust pads (2)
face operating sleeve.
Insert synchronizer in sliding sleeve halfway.
Push in balls far enough that synchronizer can be
pushed into sliding sleeve.

63023079 - click to zoom
 
Vehicles after change point in 1982
DISASSEMBLING/ASSEMBLING ENTIRE
SYNCHRONIZATION
- Output Shaft Removed -
Disassemble output shaft - see 23 21 554.
Note:
Only use molybdenum coated synchromesh
rings for repairs.
Check distance* between synchromesh ring
and clutch.
Measure in area of stops.
Note:
The synchromesh ring must be pressed on by
screwing for measurements.
Synchromesh rings must bear uniformly on
the entire surface.


Siehe auch 23 21 554
Siehe auch * See Specifications
3023101 - click to zoom
 
Disassemble synchronization.
Spring (1), thrust piece (2) and ball (3).
Installation:
Flat teeth of sliding sleeve must be aligned
with thrust pieces.

3023102 - click to zoom
 
Install all springs, thrust pieces and balls.
Important!
Shouldered end of thrust pieces faces sliding
sleeve.
Place guide sleeve halfways in sliding sleeve.
Push in balls far enough until guide sleeve can
be pressed into sliding sleeve.

3023104 - click to zoom
 
Modified Synchronization Since 5.85:
Sliding sleeves with asymmetric splines.
Thrust pieces (1), spring (2) and balls (3) in
weaker version.
Installation:
Bevelled ends of thrust pieces face the sliding
sleeve.
For the 3rd/4th gear guide sleeve it is important
to make sure that the bevelled end of sliding
sleeve faces the long collar (4) of the guide
sleeve or, for version with 3 grooves, faces the
short collar of the guide sleeve.

63023283 - click to zoom