Contents: Removal ↡ Adjusting the axial clearance ↡
Removal
1. Unscrew the 2/3 gear engagement lever.
2. Unscrew the shaft (103) of 2/3 gears and remove the engagement lever from the gearbox (120).
3. Unhook the spring (109), remove the intermediate shaft (110) and remove the driven shaft (140) from the gearbox.
4. Unscrew the 4th/5th gear engagement lever (117).
5. Unscrew the shaft (103) 4/5th gear and remove the engagement lever from the gearbox.
6. Remove the lever (5), fork (6) and clutch (15) of 4/5th gear from the drive shaft.
7. Remove the intermediate shaft (40) from the gearbox. Check the intermediate shaft for damage and wear.
8. Unscrew the nut (111) with the washer (111a) and remove the pin (106) with the locking lever (107), bushing (108), leaf spring (109) and gasket (110).
9. Remove the friction ring (126) and needle bearing (125) from the drive shaft (2).
10. Unscrew the front gearbox cover (92).
11. Remove the drive shaft (2) with the ball bearing (43) and shims (43a) forward.
12. Remove the outer bearing race (97) using a drift.
Adjusting the axial clearance
1. Install the drive shaft (2) with the ball bearing (43) and gaskets (43a) into the gearbox housing using a drift.
2. Install the intermediate shaft, driven shaft, intermediate plate, rear and front gearbox covers. After installing the drive shaft, secure the front gearbox cover (92b) with two bolts (arrows) so that the drive shaft does not fall out of the gearbox housing when installing the driven shaft.
3. Set the axial clearance of the drive shaft (2) within 0-0.1 mm. To do this, measure the distance from the edge of the bearing groove (43) to the mating surface of the gearbox using a caliper.
4. Measure the distance from the mating surface of the front cover (92) to the (4) flat surfaces (arrows) of the bearing housing. The shortest distance should be taken for the measurement. If the bearing housing is bolted to the front cover, measure the depth from the mating surface to the groove. Calculate the required shim thickness: Depth (7.00 mm) - Clearance (6.50 mm) = Difference (0.50 mm) = Washer thickness (0.50 mm). Washers are available in thicknesses of 0.2, 0.3, 0.5 mm.
5. Set the intermediate shaft axial clearance within 0-0.05 mm. To do this, measure the groove depth from the mating surface of the front gearbox cover (92).
6. Remove the outer race (97) of the intermediate shaft bearing using a drift, rotating the shaft so that the tapered roller bearing is installed correctly.
7. Measure the distance from the edge of the outer race (97) to the mating surface of the gearbox (see accompanying illustration). Determine the thickness of the shims: Depth (2.47 mm) - Gap (2.21 mm) = Difference (0.26 mm) - Gap (0.05 mm) = Gasket thickness (0.21 mm). Gaskets are available in thicknesses of 0.2, 0.22, 0.25, 0.27, 0.3, 0.32, 0.35, 0.37 and 0.5 mm.
8. Install the gaskets (94) and (96) into the front gearbox cover (92) and secure them with grease (see illustration 19.10).
9. Lubricate the mating surfaces of the front cover with sealant 002 989 00 20 (Loctite 573) and install the cover (92) on the drive shaft. Remove grease from the bolt heads and lubricate them with sealant 001 989 25 20 (Hylomar).
