Contents: Driven shaft of manual transmission…↡ Driven shaft of manual transmission…↡ Driven shaft of manual transmission…↡ Driven shaft of manual transmission…↡
Driven shaft of manual transmission according to No.0210417
Disassembly
Design of the driven shaft of the manual transmission up to No.0210417
3, 36 - Tapered roller bearings; 4 - Gasket; 5 - Impeller; 6, 30 - Retaining rings; 7 - 3rd/4th gear synchronizer; 18 - 3rd gear pinion; 20 - Driven shaft; 22 - 2nd gear pinion; 25 - 1/2 gear engagement synchronizer; 26 - 1/2 gear engagement fork; 33 - 1st gear pinion; 35 - Reverse gear pinion; 37 - 5th gear pinion
1. Remove the tapered roller bearing (3).
2. Remove the gaskets (4).
3. Press out the impeller (5) using a screwdriver.
4. Remove the retaining ring (6).
5. Remove the 3rd/4th gear synchronizer (7) and 3rd gear gear (18) with needle bearing.
6. Press out the 1st gear pinion, reverse gear pinion and tapered roller bearing. To do this, install a puller on the 1st gear pinion (33) and remove pinions (33) and (35) with the tapered roller bearing (36).
7. Remove the clutch, fork and gear shift lever. First remove the lever (29) with the gear shift fork. Remove the clutch (26) from the synchronizer.
8. Remove the retaining ring (30).
9. Remove the 1/2 gear synchronizer (25) and the 2nd gear gear (22) with the needle bearing.
10. Remove the synchronizer rings.
11. Check all removed parts for wear.
12. Clamp the drive shaft without synchronizer rings in a vice with soft jaws.
13. Install the driven shaft onto the driving shaft. Rotate the driven shaft so that the tapered bearing is installed correctly. 14. Measure the distance "a" between the limiter and the synchronizer (7) of 3/4th gear.
15. Adjust the distance "a" with shims (4), for which remove or press in the tapered roller bearing (3). The shims are available in thicknesses of 0.05, 0.1, 0.5, 0.9 and 1.2 mm.
16. Install the driven shaft into the intermediate case, rotate the driven shaft so that the tapered bearing is installed correctly.
17. Measure the distance "b" between the synchronizer (7) of 3/4th gear and the contact surface of the intermediate housing (49).
18. Remove the outer bearing ring (43) of the intermediate casing (49), insert the gaskets (44) and press the outer bearing ring again. Gaskets are available in thicknesses of 0.2, 0.3 and 0.5 mm.
Assembly
1. Assembly is carried out in the reverse order of removal. Install the coupling (26) so that the asymmetrical ends of the splines (A) are positioned towards the 2nd gear pinion (22).
2. Install the fork with the lever (29). The distance between the driving and driven shafts should be 1.5 mm, the distance between the 3rd/4th gear synchronizer and the contact surface of the intermediate housing is 138.4 mm.
Driven shaft of manual transmission from No.0210418 to No.6141000
Disassembly
Design of the driven shaft of the manual transmission from No.0210418 to No.6141000
6, 30, 180, 185 - Retaining rings; 7 - 3rd/4th gear synchronizer; 18 - 3rd gear pinion; 20 - Driven shaft; 22 - 2nd gear pinion; 23 - 1st/2nd gear synchronizer; 26 - 1/2 gear engagement fork; 33 - 1st gear pinion; 35 - Reverse gear pinion; 36 - Tapered roller bearing; 181 - Thrust bearing; 182 - Disc spring; 183 - Spring gasket; 184 - Gasket
1. Remove the retaining ring (180), thrust bearing (181), disc spring (182), spring gasket (183), gaskets (184) and retaining ring (185).
2. Remove the retaining ring (6). Retaining rings are available in thicknesses of 1.2, 1.3 and 1.4 mm.
3. Remove the synchronizer (7) of 3/4th gear and the 3rd gear gear (18) with the needle bearing.
4. Remove the 1st gear pinion, reverse gear pinion and tapered roller bearing.
5. Remove the fork with the clutch and gear shift lever.
6. Remove the retaining ring (30).
7. Remove the synchronizer (25) and 2nd gear gear (22) with the needle bearing.
8. Remove the synchronizer rings.
9. Check all removed parts for wear and damage.
10. Clamp the drive shaft (2) without the synchronizer rings in a vice with soft jaws.
11. Insert the thrust washer (123), thrust bearing (124) and needle bearing (125) without spring (121).
12. Measure the distance "a" between the limiter and the synchronizer (7) of the 3/4th gear. Adjust the distance "a" using thrust washers (124). Thrust washers (124) are available in thicknesses from 4.3 to 5.2 mm with a step of 0.1 mm.
13. Measure the distance "b" between the synchronizer (7) of 3/4th gear and the contact surface of the intermediate housing (49).
14. Remove the outer bearing race (43) of the intermediate casing (49), insert the gaskets (44) and press the outer bearing race (1) again. Gaskets are available in thicknesses of 0.2, 0.3 and 0.5 mm.
Assembly
1. Assembly is carried out in the reverse order of removal. Install the coupling (26) so that the asymmetrical ends of the splines (A) are positioned towards the 2nd gear pinion (22).
2. Install the fork with lever (29).
3. The distance between the driving and driven shafts is 1.5 mm, the distance between the 3/4th gear synchronizer and the contact surface of the intermediate housing is 138.4 mm.
Driven shaft of manual transmission from No.6141001 to No.6552834
Disassembly
Design of the driven shaft of the manual transmission from No.6141001 to No.6552834
8-3 - Shay6y; 6, 30 - Retaining rings; 7 - 3rd/4th gear synchronizer; 18 - 3rd gear pinion; 20 - Driven shaft; 22 - 2nd gear pinion; 25 - 1/2 gear synchronizer; 26 - 1/2 gear engagement fork; 33 - 1st gear pinion; 35 - Reverse gear pinion; 44 - Gaskets
1. Remove the retaining ring (6).
2. Remove the 3/4th gear synchronizer (7) and 3rd gear gear (18) with needle bearing (33).
3. Remove the reverse gear pinion (55) with gaskets (44) and the 1st gear pinion.
4. Remove the fork with the clutch and gear shift lever.
5. Remove the retaining ring (30).
6. Remove the synchronizer (25) and 2nd gear (22) with the needle bearing.
Article based on data from the website: MERCEDESMAN.ru
7. Remove the synchronizer rings.
8. Check all removed parts for damage and wear.
9. Press the driven shaft (20) into the intermediate case. Using a caliper, measure the distance "b" from the synchronizer (7) of the 3/4th gear to the contact surface of the intermediate case (49).
10. Remove the driven shaft (20) from the intermediate casing (49) using a puller and install the gaskets (44) on the driven shaft (20). Gaskets are available in thicknesses of 0.2, 0.3 and 0.5 mm.
Assembly
1. Assembly is carried out in the reverse order of removal. Install the coupling (26) so that the asymmetrical ends of the splines (A) are positioned towards the 2nd gear pinion (22).
2. Install the fork with the lever (29). The distance between the 3/4th gear synchronizer and the contact surface of the intermediate housing is 138.4 mm.
Driven shaft of manual transmission from No.6552835 to No.7011675
Disassembly
Design of the driven shaft of the manual transmission from No.6552835 to No.7011675
6, 30 - Retaining rings; 7 - 3rd/4th gear synchronizer; 10 - 3rd gear pinion; 20 - Driven shaft; 22 - 2nd gear pinion; 25 - 1/2 gear synchronizer; 26 - 1/2 gear engagement fork; 33 - 1st gear pinion; 35 - Reverse gear pinion; 36 - Hub; 37 - Spring; 45 - Gaskets
1. Remove the retaining ring (6).
2. Remove the 3/4th gear synchronizer (7) and 3rd gear gear (18) with needle bearing.
3. Remove the reverse gear pinion (35) with the gaskets (45) and the hub.
4. Remove the 1st gear pinion (33).
5. Remove the fork with the clutch and gear shift lever.
6. Remove the retaining ring (30).
7. Remove the synchronizer (25) and 2nd gear gear (22) with the needle bearing.
8. Remove the synchronizer rings.
9. Check all removed parts for damage and wear.
10. Press the driven shaft (20) into the intermediate case. Using a caliper, measure the distance "b" from the synchronizer (7) of 3/4th gear to the contact surface of the intermediate case (49).
11. Using a puller, remove the driven shaft (20) from the intermediate casing (49) and install gaskets (44) on it. Gaskets are available in thicknesses of 4.3, 4.5, 4.7 and 4.9 mm.
Assembly
1. Assembly is carried out in the reverse order of removal. Install the coupling (26) so that the asymmetrical ends of the splines (A) are installed towards the 2nd gear pinion (22)
2. Install the fork with the lever (29). The distance between the 3/4th gear synchronizer and the contact surface of the intermediate housing is 138.4 mm.
