Disassembly and assembly of the secondary shaft (Mercedes-Benz Vario 814)

The secondary shaft in disassembled condition is shown in the figure 4.20.

Figure 4.20. Secondary shaft in disassembled state: 1, 12, 16, 30, 32, 42 - Needle bearings; 2, 10, 18, 20, 26, 28, 41 - Conical synchronizer rings; 3, 19, 27 - Inner synchronizer rings; 4, 13, 17, 40, 45 - Retaining rings; 5, 21, 35 - Synchronizer clutches; 6, 24, 36 - Synchronizer crackers; 7, 22, 37 - Balls; 8, 23, 38 - Springs; 9, 25, 39 - Synchronizer hubs; 11 - 3rd gear pinion; 14, 34, 44 - Thrust washers; 15 - 2nd gear pinion; 29 - 1st gear pinion; 31 - Secondary shaft; 33 - Reverse gear pinion; 43 - 5th gear pinion.

Disassembly

1. Remove the needle bearing 1 (figure 4.21).

Figure 4.21. Remove needle bearing 1.

2. Remove the cone ring 2 of the synchronizer and the inner ring 3 of the 4th gear synchronizer (figure 4.22).

Figure 4.22. Remove the conical ring 2 of the synchronizer and the inner ring 3 of the 4th gear synchronizer.

3. Remove the retaining ring 4 (figure 4.23).

Figure 4.23. Remove retaining ring 4.

4. Remove clutch 5 together with the synchronizer hub (figure 4.24).

Figure 4.24. Remove synchronizer clutch 5.

5. Disconnect coupling 5 from hub 9 of the synchronizer and remove crackers 6, springs 8 and balls 7 (figure 4.25).

Figure 4.25. Disconnect clutch 5 from synchronizer hub 9 and remove crackers 6, springs 8 and balls 7.

6. Remove the cone ring 10 of the synchronizer (figure 4.26).

Figure 4.26. Remove the conical ring 10 of the synchronizer.

7. Remove gear 11, 3rd gear and needle bearing 12 (figure 4.27).

Figure 4.27. Remove gear 11, 3rd gear and needle bearing 12.

8. Remove the retaining ring 13 (figure 4.28).

Figure 4.28. Remove retaining ring 13.

9. Remove the thrust washer 14 (figure 4.29).

Figure 4.29. Remove thrust washer 14.

10. Remove gear 15, 2nd gear and needle bearing 16 (figure 4.30).

Figure 4.30. Remove gear 15, 2nd gear and needle bearing 16.

11. Remove cone rings 20 and 18 and inner ring 19 of the synchronizer (figure 4.31).

Figure 4.31. Remove cone rings 20 and 18 and inner ring 19 of the synchronizer.

12. Remove the retaining ring 17 (figure 4.32).

Figure 4.32. Remove retaining ring 17.

13. Remove the synchronizer sleeve together with the hub 21 (figure 4.33).

Figure 4.33. Remove the synchronizer sleeve together with hub 21.

14. Disconnect the coupling 21 from the synchronizer hub 25 and remove the crackers 24, springs 23 and balls 22 (figure 4.34).

Figure 4.34. Disconnect coupling 21 from synchronizer hub 25 and remove crackers 24, springs 23 and balls 22.

15. Remove cone rings 26 and 28 and inner ring 27 of the synchronizer (figure 4.35).

Figure 4.35. Remove cone rings 26 and 28 and inner ring 27 of the synchronizer.

16. Remove gear 29, 1st gear (figure 4.36).

Figure 4.36. Remove gear 29, 1st gear.

17. Remove the needle bearing 30 (figure 4.37).

Figure 4.37. Remove needle bearing 30.

18. Remove the retaining ring 45 and the thrust washer 44 (figure 4.38).

Figure 4.38. Remove retaining ring 45 and thrust gasket 44.

19. Remove needle bearing 42 and gear 43, 5th gear (figure 4.39).

Figure 4.39. Remove needle bearing 42 and 5th gear gear 43.

20. Remove the cone ring 41 (figure 4.40).

Figure 4.40. Remove cone ring 41.

21. Remove the retaining ring 40 (figure 4.41).

Figure 4.41. Remove retaining ring 40.

22. Disconnect coupling 35 from synchronizer hub 39 and remove crackers 36, springs 38 and balls 37 (figure 4.42).

Figure 4.42. Disconnect coupling 35 from synchronizer hub 39 and remove crackers 36, springs 38 and balls 37.

23. Remove the thrust washer 34 (figure 4.43).

[Original material on the website: MercedesMAN.ru]

Figure 4.43. Remove thrust washer 34.

24. Remove gear 33 of reverse gear (figure 4.44).

Figure 4.44. Remove reverse gear pinion 33.

25. Remove the needle bearing 32 (figure 4.45).

Figure 4.45. Remove needle bearing 32.

Assembly

26. Assembly is carried out in the reverse order of removal. When assembling, the thrust washer 34 must face downwards with its rounded surface (arrow) (figure 4.46). The protective part (arrow) of the synchronizer clutch 35 must be directed upwards (figure 4.47).