Contents: Removal ↡ Installation ↡
Removal
1. Remove the cone ring 1 and the synchronizer ring 2 of the 6th gear from the secondary shaft 11 (figure 4.71).
2. Remove synchronizer clutch 3.
3. Remove crackers 7 and springs 6.
4. Remove retaining ring 4.
5. Remove the synchronizer hub 5.
6. Remove synchronizer ring 8, 5th gear gear 9 and needle bearing 10.
Installation
7. Replace retaining ring 4, springs 6 and crackers 7. Lubricate rings 2 and 8 and needle bearing 10 with oil.
8. Install needle bearing 10 on secondary shaft 11.
9. Install gear 9 of the 5th gear on the secondary shaft 11 with the splines facing down and install ring 8 of the synchronizer on the conical ring of the 5th gear synchronizer.
10. Install synchronizer hub 5 on secondary shaft 11 so that the large locking ears on ring 8 align with the large grooves in hub 5.
11. Install retaining ring 4.
12. Install clutch 3 onto synchronizer hub 5 until it stops.
13. Insert springs 6 into the holes in hub 5 of the synchronizer and insert crackers 7 so that they fit into the teeth of clutch 3 of the synchronizer.
14. Insert synchronizer ring 2 onto hub 5 so that the large locking ears on ring 2 align with the large grooves in hub 5.
15. Install cone ring 1 onto synchronizer ring 2.
16. Set clutch 3 to neutral position.
Figure 4.71. Removing and installing the 5th gear: 1 - Cone ring: 2, 8 - Synchronizer rings; 3 - Synchronizer sleeve: 4 - Retaining ring; 5 - Hub; 6 - Springs; 7 - Crackers: 9 - 5th gear pinion; 10 - Needle bearing; 11 - Secondary shaft,
Material borrowed from an online resource [mercedesman.ru]