Secondary shaft — replacement (BMW 7 Series E32)

Removal

Disconnect the primary shaft with the roller bearing from the secondary shaft.

Remove the 5th gear with the needle bearing.

Remove the retaining ring. Remove the spacer washer. When installing, select the spacer washer so that the gap is 0-0.9 mm.

Press out the third gear pinion with the guide and sliding sleeve.

Press out the bearing sleeve and the second gear.

Remove the needle bearing and synchronizer ring.

Remove the retaining ring.

Press out the first gear pinion with the guide and sliding sleeve.

Remove the needle bearing.

Remove the reverse gear retaining ring.

Remove the needle bearing.

Examination

Check the synchronizer locking rings.

Install the synchronizer rings. Measure the gaps between the synchronizer ring and the transmission gear with a feeler gauge.

The gap is 1.0-1.3 mm from 1st to 5th gear. Minimum size is 0.8 mm. Reverse is 0.5-0.6 mm.

Minimum size 0.4 mm.

Assembly

Install the needle bearing, reverse gear and synchronizer ring.

Place the guide and sliding sleeve onto the primary shaft gear engagement.

Caution: The spring ring in the guide sleeve must face the reverse gear.

Press the guide in

Caution: When pressing in, ensure that the noses on the synchronizer ring align with the recesses in the guide sleeve.

Engage the sliding clutch in the reverse gear.

Install the guide sleeve without play using the locking ring. Locking rings from 1.7 to 2.0 mm should be used.

Install the retaining ring.

Install the needle bearing, first gear pinion and synchronizer ring.

Place the guide and sliding couplings onto the secondary shaft gear engagement.

Note: For couplings with different teeth, the protruding side must face the second gear pinion.

Press the guide sleeve into place using the bushing.

Caution: Take into account the installation position of the synchronizer ring (notch).

Engage the sliding clutch in the first gear. Install the guide clutch without play. Side rings are available.

Note: The flange of the bearing sleeve on the input shaft should protrude slightly.

Check that the retaining ring is installed correctly.

Heat the bearing race with warm air to 80°C and place it on the secondary shaft.

Install the needle bearing, third gear pinion and synchronizer ring.

Place the guide and sliding sleeves with the working edge towards the fourth gear pinion.

Press in the guide sleeve.

Caution: Take into account the installation position of the synchronizer ring (notch).

Install the spacer washer and snap ring.