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A workshop press is required for removing the constant speed gear (1) and fixed gear of 6th gear (2). The required press force is approx. 15 t.
When pressing off the constant speed gear (1), fixed gear of 6th gear (2) and synchronizer unit of 3rd/4th.gear, support countershaft (18) from underneath to protect it from falling down.
1 Attach countershaft (18), drive side upwards, with the constant speed gear (1) to the workshop press mount and press off constant speed gear (1).
2 Attach fixed gear of 6th gear (2) to the workshop press mount and press off.
3 Remove idler gear of 3rd gear (3) and needle bearing of 3rd gear (4).
4 Remove the clutch body (7), friction ring (8), cone ring (9) and synchronizer ring (10).
5 Attach countershaft (18), drive side upwards, with the 4th gear idler gear (16) to the workshop press mount.
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6 Check position of idler gear of 4th gear (16) at the workshop press mount.
Only the idler gear of 4th gear (16) may contact the mount. The collar of the roller bearing intermediate plate (arrows) must be free. If the collar is damaged when pressing off, the countershaft (18) must be replaced.
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7 Press off idler gear of 4th gear (16), synchronizer unit of 3rd/4th gear (11), thrust plate (6) and bearing bushing of 3rd gear (5).
8 Remove 4th gear needle bearing (17).
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9 Remove the synchronizer ring (12), cone ring (13), friction ring (14) and clutch body (15).
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10 Clip on the roller bearing of the intermediate plate (19) and remove.
11 Remove oil guide ring (20).