Disassembly and assembly of the intermediate shaft (Mercedes-Benz S-Class W140)

Disassembly

1. Turn the 4th/5th gear engagement lever (5) by 90° and remove it together with the fork (6) and clutch (15).



2. Using a screwdriver, remove the retaining ring (7). Remove the axial bearing (8), friction ring (9), disc spring (10), gasket (11) and retaining ring (13) from the driven shaft.





3. Reinstall the retaining ring (7).



4. Remove the retaining ring (12) of the synchronizer (14) from the driven shaft.



5. Remove the synchronizer (14), 4th gear helical gear (18) with ring (16) and needle bearing (19) from the driven shaft.



6. Remove the gaskets (36) and friction ring (35) from the driven shaft.





7. Remove the 2nd gear helical gear (33) with the synchronizer ring (31) and the needle bearing (34) from the shaft.



8. Remove the synchronizer ring from the 2nd gear helical gear.

9. Remove the 2/3 gear engagement lever with the fork and clutch. Turn the lever 90° and remove the fork.

10. Remove the retaining ring (30) of the 2nd/3rd gear synchronizer (25).



11. Remove the synchronizer (25) of 2/3rd gear and the helical gear of 3rd gear (22 with ring (23) and needle bearing (21) from the driven shaft.



12. Remove the synchronizer ring (23) from the 3rd gear helical gear (22).

Assembly

1. Install the synchronizer (25) on the driven shaft with the edge towards the 3rd gear helical gear (22) (arrow).



2. Make sure that the retaining ring (30) is correctly installed in the groove.



3. Install the 2/3 clutch (26) onto the driven shaft so that the (2) grooves face the splines.





4. The locking element of the shift lever must be installed towards the helical gear of 3rd gear (22).



5. Press the 4th gear synchronizer ring onto the helical gear until the ring spring fits into the groove.



Further installation is carried out in the reverse order of removal.

[Text republished from the website: www.MercedesMan.ru]