Removal
1. Remove the gearbox.
Disassembly
2. Disassemble the gearbox housing.
3. Remove the cone ring 6 and the inner ring 7 of the synchronizer (figure 4.19).
Figure 4.19. Secondary and intermediate shafts: 1, 17 - Bolts; 2 - Lid; 3 - Front part of the gearbox housing; 3.1 - Adjusting ring; 4 - Reverse gear shaft mounting bolts; 5 - Reverse gear shaft; 6 - Conical synchronizer ring; 7 - Inner synchronizer ring; 8 - Secondary shaft; 9 - Intermediate shaft; 10, 11 - Tapered roller bearings; 12 - Gear shift forks; 13 - Rear part of the gearbox housing; 14 - Gear shift fork mounting bolt; 16 - Pulse generator; 18 - Needle bearing.
4. Remove needle bearing 18.
5. Remove tapered roller bearing 10. Mark the location of the bearing housing.
6. Remove the secondary shaft, gear shift forks and intermediate shaft with connecting bolts.
Adjustment
7. Adjust the secondary shaft clearance (table 4.1).
Assembly
8. Install the 12 gear shift forks together. The notches (arrow) must be aligned.
Article was borrowed from the website MercedesMAN
9. Adjust the intermediate shaft clearance.
10. Install the tapered roller bearing 10. Lubricate it before installation.
11. Install the cone 6 and inner ring 7 of the 4th gear synchronizer.
12. Lubricate and install needle bearing 18.
13. Assemble the gearbox.
14. Adjust the intermediate shaft clearance (gearboxes 711.613).
Installation
15. Install the gearbox back into place.
Table 4.1. Axial clearances of shafts
| Parameters | Gearbox 711.613 |
| Axial clearance between secondary shaft bearing and locking ring, mm | 0.02-0.08 |
| Axial clearance between intermediate shaft and retainer, mm | 0; -0.06, +0.02 |