B2CJ0YK1 - 406D9 ML5T GEARBOX

DISMANTLING - ASSEMBLY OUTPUT SHAFT

1 - PRELIMINARY OPERATIONS

Remove :

• the 5th speed gear
• the gearbox casing
• the gearbox control plate
• the input and output shafts

2 - DISMANTLING

Mount the output shaft (1) in a vice fitted with soft jaws (2) .

Release then remove the output shaft nut (3) .

Remove the gear (4) for 5 th speed .

EXTRACT THE BEARING (5) USING TOOLS [4]-[22] .

Remove :

• the washer (6)
• the 4 speed driven gear (7)

Remove :

• the synchroniser ring (8) from the 4 th speed gear
• the stop ring (9), USING THE TOOL [6] - (ring thickness 3,50 mm)

Remove :

• the assembly of the hub (10) and sleeve (11) for the 3 th/ 4th synchroniser
• the synchroniser ring (12) from the 3 rd speed gear
• the 3 speed driven gear (13)

WARNING : do not separate the the hub from its sleeve to avoid ejection of the balls and springs .

Remove :

• the stop ring (14) (USING THE TOOL [6]), thickness 3,5 mm
• the 2 speed driven gear (15)
• the 1st/2nd synchroniser (16)

WARNING : do not separate the the hub from its sleeve to avoid ejection of the balls and springs .

Remove :

• the stop ring (17) (USING THE TOOL [6]) - ring thickness 2,25 mm
• the 1st speed driven gear (18)

REMOVE THE STOP RING (19) USING TOOL [6], THICKNESS 2.2 MM .

PRESS OFF THE BEARING (20) USING TOOL [22] .

3 - ASSEMBLY

WARNING : there are 2 possible stop ring thicknesses: 2,25 mm or 3,50 mm .

Fit :

• THE PLAIN ROLLER BEARING (20) IN THE PRESS USING THE FITTING TUBE [7]
• the stop ring (19), USING THE TOOL [6] (2,25 mm)
• the 1st speed driven gear
• the stop ring (17), USING THE TOOL [6] (2,25 mm)
• the 1st/2nd synchroniser (1) (engage the 3 lugs of the double synchroniser in the recesses in the gear)
• the 2 speed driven gear (15)
• the stop ring (14), USING THE TOOL [6] (3,5 mm)
• the 3 speed driven gear (13)
• the 3rd/4th synchroniser (11) with its 2 rings (follow the direction of fitting)
• the stop ring (12) USING THE TOOL [6] (3,5 mm)
• the 4 speed driven gear (7)
• the washer (6)

PRESS ON THE BEARING (5) USING TOOL [8] .

Fit the 5 th speed gear (4) .

Tighten the nut (3) to 17 da.Nm .