Assembling/Release Fork 16 S 221, 16 S 181, 8 S 181

Release fork (pulled)

9
1 Push shaft (2) into clutch bell housing. Fit new 10
tab washer (7) and grooved nut (6) onto shaft.
2 Guide shaft into 1st bearing bore on connecting 1
plate. Push release fork (1) onto shaft and guide
this into 2nd bearing bore on the connecting plate. 2
3 Place bearing bush (8) over shaft and into clutch
housing.
5
4 Hit slotted pins (4) into release fork (1) and shaft 3 6 8
(refer to assembly specification). 7
4
5 Fit tab washer (7) and grooved nut (6) onto bea-
ring bush. Secure grooved nut. 004483

Tightening torque = 200 Nm

004483
6 Fit shift lever (3) onto shaft using screw (5)
(observe position);
Tightening torque = 120 Nm.
7 Mount sheet (9) using four screws (10);
Tightening torque = 23 Nm

7
6

1 2
4 004 917
004917

3
004 918
004918

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 16 S 221, 16 S 181, 8 S 181 Assembling/Reverse Idler Gear

13 Fitting centre housing components

13.1 Reverse idler gear/reverse idler pin 3

4
5
1 Insert needle cages (1) into reverse idler gear.
2 Place reverse idler gear (2) into housing.
2
NOTE: Collar of reverse idler gear must face
towards output end. 1
3 Push reverse idler pin (3) into centre housing
from output side until firmly seated.
4 In “first version’’, screw in washer (4) and 7
locking bolt (5).
Tightening torque = 86 Nm. 6
NOTE: In “2nd version’’, the reverse idler pin is 001962
001962
secured using a centrally-mounted clamping pin
(8) (figure 002000).
5 Fit cover (6) and new gasket (7) onto centre hou-
sing.
Tightening torque = 49 Nm.

3 8

2
1
002000

13.2 Cylinder

1 Remove supporting plate and cylinder.

2 Check locking nut on piston.
Tightening torque = 150 Nm. 2
3
3 Fit spring washer (1) onto housing. 4
1
4 Fit cylinder (2) with new O-rings (3 and 4).
NOTE: If necessary, fit 3 O-rings.
Hint: Lightly oil O-rings.
5 Insert cylinder onto centre housing.
NOTE: Line up lug on cylinder with groove in
centre housing.

001963
001963

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