ZF S5-325 service manual
Contents
1. VII Assembly of the gearbox S 5 325 All components must be thoroughly cleaned before the gearbox is assembled Any residues of paint on the joint faces of housing and cover must always be removed Each component must be tested for wear or other defects and must be well greased before they are assembled Seal rings joints and tab washers must be renewed Special care should be taken that no chips or other foreign matter remain inside the housing Always use a soft hammer rubber plastic etc for driving home shafts and bolts never use a steel hammer direct on gearbox components Assemble the individual shafts and the complete gearbox in 13 reverse order to the dismantling instructions Gear wheels with collars on one side must be correctly positioned during the assembly A Assembly of reverse Clamp gearbox into bench cradle 1 Drive the reverse shaft 503 with small diameter first into the bore of the housing 101 until thrust washer 502 and the reverse gear 501 can be mounted The groove for the selector fork on the reverse shaft must point towards output side Place second thrust washer in position and drive the reverse shaft into the housing Fig 16 Make sure that the milled face of the reverse shaft is in oorrect position so that the intermediate Plate 104 can be flanged to the housing Fig 16 B Assembly and installation of layshaft Insert circlip 306 and p2. No 1248 898 204 Yoke for removing clutch body from input shaft when latter is pulled out of the housing with tool 8 Tool No 1248 898 351 Adaptor set for removing speedometer worm 442 Tool No 1248 898 202 Adaptor set for removing the sleeve carrier 438 Tool No 1248 698 206 Tool Tool Tool Tool Tool Tool Tool 2 3 14 Loa sib AT LO Adaptor set for removing the needle bearing rings 436 Tool No 1248 898 906 Adaptor set for removing 1st speed gear 424 from main shaft Tool No 1248 898 207 Thread protector for main shaft 414 Tool No 1248 898 054 Adaptor set for removing the rear taper roller bearing 304 from the layshaft 305 Tool No 1248 898 209 Adaptor set for removing the front taper roller bearing 307 from the layshaft Tool No 1248 896 208 Adaptor set for removing the helical gear 5th speed 302 from the layshaft Tool No 1248 898 205 Remover for reverse shaft 503 Tool No 1248 898 206 VI Dismantling Fig 1 1 Removal of gearshift mechanism Place gearbox into bench cradle 1 and push selector forks into neutral After unscrewing bolts 704 remove gearbox cover 707 from housing Fig 1 Unscrew 2 swivel bolts 116 and remove 5th gear selector fork 634 Fi g 2 2 Removal of main shaft and input shaft After loosening screw 809 remove speedometer drive Engage two gears remove tab washer 444 on out
3. selector tower Remove detent pins 621 compression springs 622 and balls 620 Remove slide bars 601 detent pins 602 and compression springs 603 from housing cover Remove shaft seal 120 circlip 119 and needle bearing 118 from end housing 111 and take all seal rings and shims out of ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a housing and cover Checking the individual components Test synchronizer rings 404 and 421 for wear If the rings are worn they must be exchanged for new ones Test teeth of clutch body for wear and damage All selector forks must be tested for wear if bent they should be renewed and not straightened out Test locking pawls stop bolts balls and selector bar 635 for wear Test ball and roller bearings for wear The contact surfaces of the needle bearings and the needles themselves should not show any signs of wear Input shaft and clutch body can only be exchanged as a complete unit as the clutch body is ground when mounted on the shaft Input shaft and clutch body are each punch marked Check output flange 443 for running in defects of the shaft seal 120 and the needle bearing 118 tung 5 2 amp 3 8 It the housing intermediate plate or end housing have been damaged due to improper handling they must be exchanged jointly
4. Clamp main shaft in a vice so that the long splines face downwards ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 20 Mount 2 needle cages 413 and 3rd speed gear 412 with cone towards input side Press pre assembled 3rd and 4th gear synchronizer on shaft so that inner recess of the sleeve carrier 411 face upwards Fig 24 Place circlip 410 in position Check synchronizer clearance of 1st to 5th gear with feeler gauge The clearance should be 0 6 1 mm If the clearance in too great a new synchronizer ring 404 or 421 must be installed if the clearance is too fine the synchronizer ring must be machined accordingly Engage 3rd speed gear Fig 24 E Installation of main shaft The marked position of input shaft and clutch body must also be clearly marked on the outer teeth Place clutch body with cone end into the 4th gear synchronizer ring ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a Guide the pre assembled main shaft in a slanting position and with the output side first Into the housing Fig 8 Fig 25 Press ball bearing 426 together with circlip into the housing and then press the second half of the bearing inner ring on the shaft using bearing replacer 5 Mount locking ri
5. ZF Synchroma Gearbox S 5 325 Assembly Maintenance and Operation Contents E Technical data II Description III Operation IV Maintenance V Tools VI Dismounting and checking individual members VII Assembly and operational check VIII Ordering of spare parts IX Key to illustrations and exploded view X Service stations I Technical data max input torque 44 mkg 317 ft 1b Ratios lst speed 2 73 2nd speed 1 76 3rd speed 1 23 4th speed 1 0 5th speed 0 83 reverse 3 31 speedometer 1 75 lst to 5th gear synchro mesh reverse with sliding gear Weight of gearbox approx 56 kg 123 1b Oil capacity approx 2 0 litres 3 5 pints Ver Tools Tool 1 Bench cradle Tool No Tool 2 Bearing replacer for front taper roller bearing 307 on layshaft Tool No 1248 898 051 Tool 3 Bearing replacer for rear taper roller bearing 304 on layshaft Tool No 1248 898 052 Tool Tool Tool Tool Tool Tool Tool Tool 10 11 Guide bush for synchronizer body 1st and 2nd gear Tool No 1211 898 001 Replacer for roller bearing inner rings bearing bush 436 sleeve carrier 438 and speedometer worm 442 on input shaft Tool No 1248 898 053 2 distance pieces for protecting the synchronizer rings during replacement of input shaft Tool No 1248 898 101 Remover main tool used in conjunction with tools 10 to 17 Tool No 1248 898 201 Input shaft remover Tool
6. altung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 23 of housing and also measure the depth of the respective recess in the intermediate plate 104 For this purpose the joint 102 must be placed on the intermediate plate The difference between both measurements plus the initial stress of 0 03 0 05 mm will be the thickness of the shims 303 which are placed in the recess of the intermediate plate The shims are available in sizes 0 05 0 1 0 2 0 5 and 1 0 mm Fig 28 Push ball bearing 426 into the housing until the circlip 427 abuts Determine thickness of shims 428 in a similar manner as for the roller bearing of the layshaft Since in this case the distance of a ball bearing has to be adjusted the initial stress of 0 03 0 05 mm is omitted Figs 27 and 28 The shims are also placed in the recess of the intermediate plate They are available in sizes 0 1 and 0 15 mm Again check 4th gear synchronizer clearance and if necessary adjust Attach Joint 102 ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a with some grease to the intermediate plate Place intermediate plate with the inserted shims on the gearbox housing tighten the 8 screws 110 and secure with tab washers 108 Knock set pins 103 which are used for centering the end housing into
7. ase to the sliding surface of the shaft above collar Push the 2nd speed spur gear 417 over the two split bearings so that the conical end points towards output side facing upwards Place thrust washer 419 on helical gear so that the two oil grooves are facing downwards Fig 21 Fig 22 Turn the thrust washer so that the milled slot on one of the internal splines of the thrust washer is in line with the keyway ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 19 on one of the main shaft splines Place the key with some grease into the keyway of the shaft spline as shown in Fig 22 The small and of the key must fit into the recess out into the thrust washer 419 Fig 23 Place pre assembled 1st and 2nd gear synchronizer and spur gear on the main shaft using guide bush 4 Fig 23 This guide bush presses the inner balls 409 previously placed in the through bores of the synchronizer body outwards Under no circumstances should the balls rest against the shaft key 415 Gear teeth of spur gear must face upwards towards output side Mount the 2 needle bearings 413 and the lst speed gear conical surface towards synchronizer Place thrust washer 425 with oil grooves on the gear Using bearing replacer 5 press one half of the bearing inner ring ball bearing 426 on the main shaft
8. at the surface which will be joined to the housing faces upwards Push slide 601 with stop notch upwards into the transverse bore in the selector tower Place 5th speed selector bar 636 short bar with lug on its end into the outer bore of the centre cross piece and compression spring 622 and bolt 21 into the bottom bore Press the selector bar past the detent and push it along until the spring 637a and the driver 637 can be fitted screw the qrub screw through the driver and into the bore of the selector fork Put selector bar into neutral Guide the longest of the 4 selector bars 19 through the bore for the reverse light switch until the reverse gear driver 623 can be fitted before the bar has reached the first cross piece Push the selector bar up to the centre cross piece place compression spring 622 and bolt 21 into ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 28 the bottom bore of the centre cross piece and then press the selector bar past the detent Fit selector fork 618 and push the selector bar through until the bolt can slide into the slot provided for this purpose Screw grub screw 617 through the driver 623 respectively through the selector fork 618 and into the bores of the selector bar Put selector bar into neutral Place two balls into the transverse bore i
9. chronizer body one ball 409 one compression spring 408 these are 0 7 mm shorter than those in the blind holes and then attach another ball with some grease Push sleeve carrier 411 into the bore of the synchronizer body taking care that the two balls are pressed into the bore b 1g and 2nd gear synchronizer body The synchronizer for the 1st and 2nd gear is assembled as described above with the exception that in place of the sliding sleeve 402 the spur gear 423 is pushed over the synchronizer body 422 A sleeve carrier is not necessary as the synchronizer body in placed direct on the main shaft 414 c The 5th gear synchronizer is only required to operate in one direction its design however is similar to the 3rd and 4th gear synchronizer The stops of the sleeve carrier 438 which is used with this synchronizer must rest against the synchronizer body on the ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 18 opposite side of the synchronizer ring 404 when the sleeve carrier is placed in position In place of the second synchronizer ring a disc 439 is used and this is secured with a circlip 403 D Assembly of main shaft Fig 21 Clamp main shaft 414 with long splines pointing upwards ina vice Use lead jaws Secure the two special split bearings 417 with some gre
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11. e left to our discretion A clearly expressed order is as follows I hereby order for gearbox S 5 325 gearbox No 135 1 complete input shaft 1248 202 900 consisting of complete input shaft 1248 202 006 clutch body 1248 302 007 Dispatch immediately by express Orders made by telephone or telegraph must be confirmed in writing Dispatch is made at Purchaser s risk even if no charge is made for the spare parts Spare parts are only supplied free of charge during the guarantee period provided that on examining the part it is found that the damage was due to faulty manufacture or 34 defective material For this reason the faulty part must be returned to us for testing without having been tampered with and all carriage paid Faulty samples will be scrapped unless their return is especially requested when they are sent to us Terms of payment Cash on delivery L 81 64 5unipupsleddnuy STE SS 3dSHISO DUJOJUDuAG Bung S 47 5upu 4039 1 9J1 GZE GS xog 10 9 DUJOJJOuAS peedS G Z WS D wf zu K Soe D S08 NER ums SIUD Go ll SUoIssiwsung 10 OZI UM MOIIAAS 51461 Y90q INOPIA SUOHSSIUJSUDJ 10 ZIL PUD ILL SOJ J POYISIYRPYOPPNY HW 39311139 any OZIL VA J NDUISIYIUONY SUMO 393139 IN ZIL E e TLL aa O 2 amp e p BL By Buryjpupsjeddnuy GZE GS adeleg DuJOJJoUAS Budd G 47 u 6 unzoy gt spo yusjsyur 216 f I SZT SYY 16 f
12. ents and sleeve carrier 411 Withdraw 3rd speed gear 412 Fig 12 and both needle bearings 413 from shaft Take main shaft out of vice Fig 13 Remove 1st speed gear 424 using tool 7 together with adaptor set 13 and thread protector 14 Fig 13 Lift the 2 needle cages 413 over the splined section and remove reverse spur gear 423 together with the synchronizer components taking care not to lose the key 415 Remove 2nd speed gear 418 and split needle bearing 417 Fig 14 5 Disassemble the synchronizer components Press spur gear 423 respectively sliding sleeve 402 from synchronizer body 422 or 406 taking care not to lose the 6 balls 409 and the 4 springs 497 and 408 which are liable ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 10 to jump out It would be advisable to cover these components with a cloth so that they cannot got lost Release circlips 403 and remove synchronizer rings 404 and 421 and the locking Pawls 405 Fig 14 Fig 15 6 Dismantling cover and gearshift mechanism Unscrew hexagon nuts 615 and remove selector tower 612 and selector lever 607 Remove reversing light switch Remove all cover plates 702 Loosen all grub screws 617 on the selector forks and drivers Fig 15 and knock out the selector bars from the rear
13. h which during the synchronizing process press the pawls upwards The sliding sleeve must be placed over the pre assembled synchronizer body so that one pawl will always lie between the two locking teeth Fig 20 Moreover the looking teeth must lie behind the pawl as ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 16 viewed when the pre assembled synchronizer body is lying in a horizontal position on a plate The 2 pawls which are enclosed respectively carried along by the upper synchronizer ring must lie above the locking teeth Locking teeth therefore in lower half of sliding sleeve The two other pawls which are carried along by the lower synchronizer ring lie below the locking teeth Locking teeth therefore in upper half of sliding sleeve It is also most important that the teeth of the sliding sleeve which are chamfered at both ends always lie over the balls in order to prevent the balls from binding when the gears are disengaged When the sliding sleeve has been mounted incorrectly upside down the chamfered teeth are lying next to the balls and not over the balls From the inside place into each of the 2 through bores of ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a the syn
14. ment of the reverse gear the gearshift lever must be lifted upwards Checking neutral position of reverse gear For this purpose the gearbox must be lifted at the input shaft and the 2nd speed gear must be engaged Check whether the reverse gear scrapes against the reverse spur gear 423 when the input shaft is turned If this is the case nut 627 must be unscrewed and the eccentric pin 624 must be adjusted The reverse gear operating lever 625 must be adjusted so that 2 32 the reverse gear does not scrape against the reverse spur gear and the gearshift lever does not bind in neutral VIII Order for spare parts In order to achieve a speedy and correct delivery of spare parts orders should contain the following details 1 Gearbox type S 5 325 2 Gearbox No this is stamped gearbox housing cover 3 Designation of required spare exactly an given in the spare manual 4 Part No This is the 10 digit the spare part to be replaced 5 If one or several indications on the type plate on the parts Name the spare part parts list and instruction number stamped on or cast in of point 1 4 cannot be given the following details are important a Reference No given in the instruction manual 35 b Make and type of vehicle and name of firm which manufactured the chassis 6 Method of dispatch by post freight express etc otherwise the method of dispatch will b
15. n the centre cross piece between the reverse selector bar and the 1st and 2nd speed selector bar Guide 1st and 2nd speed selector bar 629 bar with recess for 5th speed selector bracket into the bore next to the reverse gear selector bar Fit driver 630 and place spring 622 and bolt 621 into the bottom bore in the centre cross piece Push selector bar through and secure selector fork 628 and driver with grub screws Put selector bar into neutral ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 29 Place two balls into the transverse bore in the centre cross piece between the 5th speed selector bar and the 3rd and 4th speed selector bars Place also two balls between 1st and 2nd speed selector bar and 3rd and 4th speed selector bar Fit 3rd and 4th speed selector bar 632 The 3rd and 4th speed selector bar must be pushed through the bore of the lug on the selector bar 5th speed and through the reverse selector fork Turn the housing cover so that it rests on the selector forks Place bolt 606 from the outside into the bore of the ball socket 604 Place the bell socket into the recess of the cover so that the threaded pin can be screwed through the threaded bore in the cover and into the hollow of the ball socket Place the complete gearshift lover 607 into the ball socket Fit sp
16. ng 429 and tighten lock nut 430 with lock nut key Engage two gears Secure look nut F Mount input shaft Place circlip 203 into the radial groove of roller bearing 204 Press first the roller bearing and than the ball bearing 202 on the input shaft 205 Screw on lock nut 201 Place needle bearing 401 on end of main shaft and push the input shaft through the housing bore In order to protect the synchronizer rings 404 place one distance piece 6 in front and the other behind the sliding ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a sleeve Fig 26 Fig 26 With the aid of a soft hammer drive the input shaft according to the position markings into the internal teth of the clutch body Tighten lock nut 201 with commercial lock nut spanner and secure by driving the locking ring into the longitudinal groove of the input shaft Push oil collector pipe 115 from input side into the housing bore The open side of the bisected pipe points upwards and inside G Mount Intermediate Plate Fig 27 Drive the layshaft towards input side until the front bearing 307 is flush with the joint face of the housing Push home outer ring of rear roller bearing 304 Measure distance from outer ring of rear bearing to joint face ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelsch
17. ntermediate plate and the other set screw into the long bore of the end housing Push the end housing over the main shaft and move it about until the set screw sitting in the bore of the end housing ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 26 can also be screwed into the thread of the intermediate plate Secure end housing with screws 109 and 112 and the 2 hexagon nuts 105 Place spring washers 106 below the screws 112 and below the nuts 105 The two screws 109 are secured with tab washers 108 Push output flange 443 on the splined section of the main shaft and secure with hexagon screw 445 and tab washer Fit speedometer drive and secure with hexagon screw 809 and tab washer 808 Place the two sliding pieces 635 into the bores of the 5th speed selector bracket 634 Fig 31 Guide the pre assembled selector bracket into the 5th gear sliding sleeve 402 so that the selector finger engages the 5th gear selector bar Fig 31 and the swivel bolt 116 with the seal rings 117 can be screwed in Check selector fork for ease of operation ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a K Assembly of selector mechanism and housing cover Place the housing cover 701 on a bench so th
18. put flange 443 and hexagon screw 445 and withdraw flange Unscrew hexagon bolts 109 and 112 and nuts 105 of end housing 111 Fig 2 Remove one of the two set screws 107 so that the housing can be shifted slightly and then removed ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a Fig 3 Release circlip 440 and remove speedometer worm 442 from output shaft using tool 7 and adaptor set 9109 Fig 3 Release second circlip 440 Fig 4 Remove distance bush 441 and release third circlip 440 on 5th speed gear Using main tool 7 and adaptor set 11 withdraw complete 5th speed gear synchronizer body 406 placing remover on sleeve carrier 438 Fig 4 Remove main shaft key 416 and withdraw 5th speed gear 437 together with needle cage 413 Fig 5 Withdraw bearing bush 436 from shaft using main tool 7 and adaptor set 12 Fig 5 and remove thrust washer 435 Fig 6 Release circlip 301 and withdraw 5th speed layshaft gear 302 using main tool 7 and adaptor set 17 Loosen screws 110 and remove Intermediate plate 104 Unbend looking piece 429 engage two gears and unscrew look nut 430 with a commercial hook spanner Fig 6 Remove look nut 201 on input shaft 205 in the same manner Fig 7 Put sliding sleeves into neutral and place tool 9 be
19. ress the small roller bearing 307 on input end of layshaft 305 using bearing replacer 2 Fig 17 Guide layshaft with input end first in a slanting position into the housing Fig 10 With the aid of bearing replacer 3 press the rear roller bearing 304 on the shaft Fig 18 Drive outer bearing rings of front and rear roller bearings into the housing using a soft hammer Fig 17 Fig 18 C Pre assemble synchronizer Fig 19 a 3rd and 4th gear synchronizer body 1 Place synchronizer rings 404 offset against each other by 90 on the synchronizer body and place circlips 403 in position Make sure that the synchronizer rings can turn easily The position of synchronizer rings to synchronizer body is optional Place the 4 locking pawls 405 into the recesses of the ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 15 synchronizer rings so that the inner conical point of the pawl points towards the centre of the synchronizer body Fig 19 Fig 20 2 Place the two longer compression springs 407 into the blind holes of the synchronizer body and attach one ball 400 with some grease to each compression spring Before the sliding sleeve 402 is mounted the following points must receive consideration Four times two adjacent tooth of the sliding sleeve are designed as locking teet
20. ring 608 washer 609 rubber gasket and spring ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a washer 610 to ball end Place bolt 602 and spring 603 into the bore of the gearshift cover Guide gasket 611 and selector tower 612 over the threaded pins 613 and secure with nuts 615 and spring washers 614 Pull rubber grommet 616 over the selector tower and screw on selector lever knob L Connect pre assembled housing cover to gearbox housing Put selector sleeves and reverse gear into neutral Make sure that the selector forks are also in neutral Place housing cover on gearbox housing making sure that all selector forks engage with the sliding sleeves and that the fork for reverse engages with the bolt of the 5th speed selector bracket Fig 32 Secure cover with screws 704 and spring washers 703 Fit magnetic plug 113 and oil dip stick 114 ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a Fig 32 Operational check Engage all gears successively During this procedure turn the input shaft and check that the output flange is carried along in each gear During the engagement of 1st and 2nd gear and also during the engagement of the 5th gear a detent must be overcome For the engage
21. the bores of the intermediate plate H Mount 5th speed gear Fig 29 Press the layshaft gear 302 with the cylindrical recess first on the shaft Fig 29 and insert circlip 301 Fig 30 Place thrust washer 435 with oil grooves towards output side against lock nut 430 and press bush 436 on the main shaft using tool 5 Slide needle bearing 413 and 5th speed helical gear 437 over bush 436 so that the conical rim faces towards the output side With the aid of a soft hammer drive two Woodruff keys 416 into the main shaft Mount pre assembled ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a 25 synchronizer body synchronizer ring facing towards 5th speed gear using tool 5 Fig 30 Projection on sleeve carrier facing towards output side Place circlip 440 into radial groove behind the sleeve carrier Slide distance bush 441 over the main shaft and place 2nd circlip 440 in position With tool 5 press speedometer worm 442 on the shaft until it rests against the 2nd circlip and secure it with the 3rd circlip I Mount end housing Press needle bearing 118 into neck of end housing Place circlip 119 in position and press in shaft seal 120 until it rests against the circlip Lip of seal ring towards outside Insert one set screw 107 into the thread of the i
22. tween housing wall and 4th speed clutch body on input shaft Withdraw Input shaft with the aid of tool 8 Fig 7 Press bell bearing 202 and roller bearing 204 from input shaft and remove needle bearing 401 from end of main shaft Using a rubber hammer drive the main shaft with light blows 2 3 mm towards the input side and remove the ball bearing 426 Fig 8 Lift the main shaft and all its components with input side first in a slanting position out of the housing Fig 8 Fig 9 Fig 10 3 Removal of layshaft and reverse With a soft drift drive the layshaft towards the rear until roller bearing 304 on input aide is free of the housing Remove inner ring of roller bearing 304 with main tool 7 and adaptor set 15 Fig 9 Take the layshaft with the large gear wheel first out of the gearbox housing Fig 10 Remove front roller bearing 307 from the shaft using main tool 7 and adaptor set 16 Fig 11 Release circlip 306 Withdraw reverse shaft 503 with tool 18 and remove reverse gear 501 and thrust washer 502 Fig 11 Fig 12 4 Dismantling the main shaft Clamp main shaft at splined section vertical in a vice with soft ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Rg 18 Va ZF 5 Gang Synchroma Getriebe S5 325 Kn ppelschaltung Fig 18 2 a jaws Release circlip 410 on sleeve carrier Remove sliding sleeve 402 together with synchronizer compon
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