5th Gear, Installing For Assembly
- Make sure the Bracket - Multiple Use 30-211A and the Support Bridge T10323 are installed.
-- Secure the bolt on the Bracket - Multiple Use 30-211A with the nut -A- .
5th Gear, Installed Position
The groove all the way around -arrow- faces the transmission housing.
-- Heat the 5th gear to approximately 100 °C (212 °F) using the inductive heat unit VAS 6414.
Wear safety gloves.
-- Install the 5th gear.
Checking the 5th Gear Synchronizer Ring
-- Before reinstalling 5th gear and synchronizer ring, press the synchronizer ring onto the taper of the gear and measure the gap dimension -a- using a feeler gauge.
| Gap dimension -a- | Installed dimension | Wear limit |
|---|---|---|
| 5th gear | 1.1 to 1.7 mm | 0.5 mm |
-- Install the 5th gear selector gear with needle bearing.
-- Place the 5th gear synchronizer ring onto the selector gear.
-- If disassembled, assemble the 5th gear locking collar/synchronizer hub, refer to Figure.
Installed Position of the 5th Gear Synchronizer Hub/Locking Collar
The pointed teeth on the locking collar -arrow 1- and the high collar on the synchronizer hub -arrow 2- face the transmission housing.
The notches -arrow 3- on the synchronizer hub must line up with the cast locking pieces on the synchronizer ring, refer to Figure.
5th Gear Synchronizer Ring with Cast Locking Pieces
-- Cover all openings with cloths to prevent foreign objects from getting into the transmission.
-- Heat the 5th gear synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit VAS 6414.
Wear safety gloves.
-- Install the 5th gear synchronizer hub
Make sure there is enough clearance when installing the synchronizer ring.
-- Loosen the support for the input shaft.
-- If it has not been done already, clean any locking fluid residue from the threaded hole for the synchronizer hub bolt and 5th wheel with a thread tap.
Otherwise, there is the danger that the bolts could shear off.
-- Install the new synchronizer hub bolts and 5th gear.
Installed Position of the Concave Washers for 5th Gear and the 5th Gear Synchronizer Hub Bolts
The outer diameter -arrows- faces 5th gear.
-- Engage 5th gear -arrow 1- and 1st gear -arrows 2 and 3- and then tighten the bolts -A- for the synchronizer hub and the 5th gear to specification, see -item 4- in TRANSMISSION HOUSING COVER AND 5TH GEAR OVERVIEW .
-- The input shaft and the output shaft are blocked after both gears are engaged. The synchronizer hub and the gear cannot turn. Both bolts can now be tightened
-- Install the 5th gear selector fork.
Adjusting 5th Gear
-- Shift into gear. Loosen the bolt -1- . Push the locking collar and the selector jaw in the -direction of the arrow- . Tighten the bolt -1- to 25 Nm.
- Measurement check: it must not be possible to slide a 0.2 mm feeler gauge between the locking collar and drive gear. Repeat the adjusting procedure if necessary.
-- Install 5th gear. The locking collar must be in the neutral position. The synchronizer ring must move freely.
-- Move the shift lever through all the gears.
-- Install the transmission housing cover, refer to TRANSMISSION HOUSING COVER AND 5TH GEAR OVERVIEW .
-- Install the release bearing guide sleeve, refer to CLUTCH RELEASE MECHANISM OVERVIEW .
-- Install the clutch release lever and release bearing, refer to CLUTCH RELEASE MECHANISM OVERVIEW .
-- Fill the transmission fluid, refer to TRANSMISSION FLUID, CHECKING AND FILLING .