Cars with engines 111.948 and 601.970
Disassembly
1. Disassemble the gearbox.
2. Unscrew bolt 2 (see figure 6.25).
Figure 6.25. Drive shaft (cars with engines 111.948 and 601.970):
1. Drive shaft (assembled),
2. Bolt,
3, 16. Ball bearing,
4. Gaskets,
5. 5th gear synchronizer clutch,
6. Needle bearing,
7. Bearing sleeve,
8. Synchronizer ring,
9. 5th gear pinion,
10, 14. Retaining gasket,
11. Ball,
12. 4th gear pinion,
13. 3rd and 4th gear synchronizer clutch,
15. Thrust bearing (green/black),
17. 3rd gear pinion,
18. Val.
3. Install plate 19 between synchronizer ring 8 and toothed wheel 12 (see figure 6.26).
Figure 6.26. Drive shaft (cars with engines 111.948 and 601.970):
10. Thrust gasket,
11. Ball,
12. 4th gear pinion,
19. Removable plate.
4. Install the thrust piece, press out the ball bearing 3, 5 and gears 12 and 9. Bushings 7 and needle bearing 6 of the 4th and 5th gears are the same, but it is not recommended to mix them. Also do not mix the 4 drive shaft gaskets with the same ones for the driven shaft.
5. Remove ball 11.
6. Disassemble the 5th gear synchronizer clutch. To do this, remove the sliding sleeve 5 from the synchronizer housing 1 (see figure 6.27). Remove spring 2 and retaining ring 4.
Figure 6.27. Disassembling and assembling the 5th gear:
1. Synchronizer housing,
2. Spring,
3. Ball,
4. Retaining ring,
5. Sliding sleeve.
7. Press out bearing sleeve 7, synchronizer sleeve 5 and gear 17.
8. Remove roller 16 and thrust 15 bearings.
9. Disassemble the clutch 13 of the synchronizer for engaging 3rd and 4th gears; to do this, remove the sliding sleeve 4 from the synchronizer housing 1 (see figure 6.28). Remove spring 2 from synchronizer housing 1.
Figure 6.28. Disassembly and assembly of the 3rd and 4th gear engagement mechanism:
1. Synchronizer housing,
2. Spring,
3. Ball,
4. Sliding sleeve.
10. Check the wear between the synchronizer ring 8 and the 5th gear pinion 9 (see figure 6.29). It should be 0.8 mm. Replace them if necessary.
Figure 6.29. Checking the wear between the inner synchronizer rings and the 5th gear:
1. 5th gear pinion,
2. Synchronizer ring,
3. Probe.
Assembly
11. Lubricate all bearings with oil before installation.
12. Insert thrust bearing 15. In the original condition, thrust bearing 15 of 2nd gear is black, and thrust bearing in synchronizer clutch 13 is green. New bearings 15 are green.
13. Insert both roller bearings 16 and gear 17.
14. Insert synchronizer ring 8.
15. Insert thrust bearing 15.
16. Insert synchronizer sleeve 13 into the synchronizer housing with the larger cuff facing up and press it in. The guide rings 8 of the synchronizer must engage with the recess of the synchronizer housing. During pressing, lift gear 17 to correctly install thrust pad 14 and thrust bearing 15.
17. Install synchronizer sleeve 13. Press sliding sleeve 4 onto synchronizer housing 1 and make sure that the groove (arrow) matches the 3rd gear pinion (see figure 6.28). Insert springs 2 into synchronizer housing 1. Compress springs 2 and insert balls 3. Insert the 4th gear synchronizer ring, press back and set sliding sleeve 4 to neutral position.
18. Insert synchronizer ring 8. The guide rings 8 of the synchronizer must engage with the recess of the synchronizer housing.
19. Press in bearing sleeve 7 until it stops and insert needle bearing 6.
20. Insert gear 12.
21. Insert ball 11 and thrust washer 10.
22. Press in bearing sleeve 7 until it stops and insert needle bearing 6.
23. Install gear 9.
24. Insert synchronizer ring 8.
25. Insert synchronizer sleeve 5 into the synchronizer housing and press it in with the locking ring facing up. The guide rings 8 of the synchronizer must engage with the recess of the synchronizer housing.
26. Install synchronizer sleeve 5. Press sliding sleeve 5 onto synchronizer housing so that the groove (arrow) coincides with the 5th gear pinion (see figure 6.27). Insert springs 2 into synchronizer housing 1. Compress springs 2 and insert balls 3. Insert synchronizer retaining ring. Set sliding sleeve 4 to neutral position.
27. Install the removed gaskets 4.
28. Press in ball bearing 3 with groove facing up.
29. Screw in bolt 2. Lubricate the threaded part of bolt 2 with Loctite 243 adhesive.
30. Assemble the gearbox.
Cars with engine 611.980
Disassembly
31. Disassemble the transmission.
32. Disassemble the synchronizer clutch 2 5th gear (see figure 6.30). to do this, remove the retaining ring 4 (see figure 6.31). Press out sliding sleeve 2 through the bottom of synchronizer housing 1. Remove locking pins 3.
Figure 6.30. Drive shaft (cars with engine 611.980):
1. Drive shaft (assembled),
2. 5th gear synchronizer clutch,
3. Synchronizer ring,
4. 5th gear pinion,
5. Needle bearing,
6, 8. Bearing sleeve,
7. 4th gear pinion,
9. 3rd and 4th gear synchronizer clutch,
10. Thrust gasket,
11. Thrust bearing,
12. Ball bearing,
13. 3rd gear pinion,
14. Drive shaft.
Figure 6.31. Disassembling and assembling the 5th gear (cars with engine 611.980):
1. Synchronizer housing,
2. Sliding sleeve,
3. Locking finger,
4. Retaining ring.
33. Press out the synchronizer housing using the removable plate 16 (see figure 6.32).
Figure 6.32. Drive shaft (cars with engine 611.980):
15. 4th gear pinion,
16. Removable plate.
34. Remove gear 4-5 with synchronizer ring 3. Check the synchronizer ring for wear (see figure 6.29). It should be 0.8 mm.
Information copied from the website (Mercedesman.ru)
35. Remove needle bearing 5 and sleeve 6 from drive shaft 14.
36. Disassemble the synchronizer clutch 9 for engaging 3rd and 4th gears. To do this, press the sliding sleeve 2 down from the synchronizer housing 1 (see figure 6.33). Remove locking pins 3.
37. Press out the synchronizer ring.
38. Remove needle bearing 5 and sleeve 8.
39. Remove thrust pad 10 and thrust bearing 11.
40. Remove gear 13 of 3rd gear with synchronizer ring. Check the synchronizer ring for wear (see figure 6.29).
41. Remove both roller bearings 12.
42. Remove thrust bearing 11.
Assembly
43. Lubricate all bearings with oil before installation.
44. Install thrust bearing 11, both roller bearings 12, 3rd gear pinion 13, synchronizer ring 3, thrust bearing 11 and thrust lining 10.
45. Install the synchronizer housing with the larger cuff facing up and press it in. The guide rings 8 of the synchronizer must engage with the recess of the synchronizer housing.
46. Assemble the 3rd and 4th gear synchronizer clutch 9. To do this, install the sliding clutch 2 on the synchronizer housing 1 with the groove (arrow) facing up so that it coincides with the 1st gear pinion (see figure 6.33). Insert locking pins 3 under pressure. Set sliding sleeve 2 to neutral position.
Figure 6.33. Disassembling and assembling the 3rd and 4th gear engagement mechanism (cars with engine 611.980):
1. Synchronizer housing,
2. Sliding sleeve,
3. Locking finger,
4. Retaining ring.
47. Install needle bearing 5 and sleeve 8 on drive shaft 14.
48. Press synchronizer ring 3 into sleeve 8 until it stops and insert needle bearing 5.
49. Install gear 7 of 4th gear.
50. Press in sleeve 6 until it stops and insert needle bearing 5.
51. Install gear 4 of 5th gear.
52. Install synchronizer ring 3.
53. Install the 5th gear synchronizer sleeve 2 onto the synchronizer housing and press it in so that the groove of the retaining ring is facing upwards.
54. Install the 5th gear synchronizer clutch 2.
55. Assemble the gearbox.