Transmission, assembling: Notes

If transmission housing, gear set or hollow shaft was replaced, you must first redetermine the thickness of the shim " S ₆ " → Shim " S 6 " for positioning 2nd gear selector gear, redetermining . It is located on the hollow shaft and is responsible for position 2nd gear selector gear.

If gear set is replaced, then always replace double angular contact ball bearing on drive pinion with it.

To check double angular contact ball bearing for wear (running noise), differential must be removed. When turning the installed drive pinion, the bearing must not catch and must run smoothly.

NOTE:

All threaded bores in which self-locking bolts are threaded must be carefully cleaned of remaining locking fluid using a tap.
Clean threads on hollow shaft for twelve-point nut.
Lubricate all needle bearings and synchronizer rings with transmission fluid before inserting.
Housing joint surfaces must be cleaned.
Checking synchronizer rings for wear → Drive pinion and hollow shaft, assembly overview .

Place shim " S ₃ " in transmission housing.

Fig 1: Removing Drive Pinion From Bore In Transmission Housing

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Coat outer races - 3 - and - 4 - with transmission fluid.
Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.

NOTE:

Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.

Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.

If the double angular contact ball bearing seal is damaged, the bearing must be replaced.

Fig 2: Identifying Bolts & Retainer Plate

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Insert shim " S ₄ " and retainer plate - A - , only fits in one position.
Clean threads of previous screws - arrows - with a wire brush. Then insert screws with locking compound AMV 185 101 A1 and tighten in diagonal sequence to 30 Nm.
Place hollow shaft needle bearing on drive pinion.

Fig 3: Guiding Hollow Shaft Together With Input Shaft And Selector Rods Upward Over Drive Pinion

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Insert hollow shaft - 1 - together with input shaft - 2 - and selector rods - 3 - and - 4 - in transmission housing and at the same time, guide hollow shaft over drive pinion - arrow -.

Fig 4: Placing Oil Pan With Ridge In Notch In Transmission Housing

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Place oil pan - 1 - with ridge - arrow A - in notch - arrow B - in transmission housing.

Fig 5: Removing/Installing Bearing Bracket With Reverse Shaft Mount & Oil Pan

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Guide bearing bracket - A - over input shaft and hollow shaft and place on oil pan - C -.

Reverse shaft mount - B - must be installed on bearing bracket.