M 45 4-speed Secrion Group

4 43

M 46 4-speed (M 45 + overdrive) Manual

Transmissions
M45/M46

Repairs and Maintenance 1979-

 Group 43: Manual transmission

M 4 5 "" Stan dard tran sm iSSion (I n troduced on 1979 modeis)

M 4 6 = Standard tran smiSSion w it h overdnve unlt attached
(M 4 5 + overdnve)_

Repalf mSl ruct lons tor Overd rive are [Link] In separate manual

Contents
Page

•
Specifications

Special tools 2
- Mod ,f leatlons 10 flll;lure 5 130 4
Spare parts illustrations 5

•
TransmiSSion assembly 6
TransmiSSIOn parts 8
- TransmisSion contrals 10
TransmiSSion mOllnts 12
Features. M 45 / M 46 1979- 14

Service procedures: Operation

- M 45 replacrng rear seal
In [Link] Al - AS 20
M 45 ! M 46 replacrng back-up light
SWitch In veh_cle 81 - 8 13 22
- M 4 5 1 M 4 6 re palr~ to gearshdt
lever In vehlcle el - Ct7 25

M 45 , removal 0 1- 0 17 31
M 45 dlsassembly El - E41 35

•
M 45 assembly Fl - F6B 45
M 45 Instal lation Gl- G15 61

M 46 remOval Hl - H1 9 61
M 46 dlsassembly 11 - 138 69

•
M 46 assembly J 1- J69 78
M 46 InSlallauon K l - K1 8 94

I Indicate s changes in text and/or specification in this manual.

TP 30056/2
4500.04.84
Printed n U.S.A. •
 Specific8tions
l
Specifications

General
Type . M 45 M 46 Late Models
Gear ratios'
lstgear . . " ........... , ... _, _ 3711 3 .711 4.03; '
2ndgear .. 2 . 16 ; , 2 . 161 2. ' 6; '
3rd gear 1.37 1 1.37 , 1.37:1
4th gear ,_ 1; 1 1: 1 ,;,
4th gear + overdrive . 0 .797 ; , 0.797; '
Reverse gear ...... , ..... " .... ", .... , ..... " ..... , .... . 3 .68 ' 3 .681 3.68;'

lubricant Merric US Measuremenrs

Type . Automatic Transmission Fluid
TypeForG
CapacIty . M 4 5 ... 0 .75 liter 0 .8 US qt.
Capacity : M 4 6 .. 2 .3 fiters 2 .4 US qts .

Clearances
Clearance between reverse gear and shift tork .. 0 . 1- 1.0mm 0 .004"-0 .0 4 "
Axial clearance
Input shaft . 0 .0 1-0.20 mm 0 .0004-0.008 "
Intermediate shaft . 0 .025- 0 . l O mm 0 .00 ' - 0 .004 ' ·
Main shaft ......... ,.... " ..... ,............ ,., .................. , ..... . 0 .0 1- 0 .20 mm 0 .0004-0.008··

Aluminum transmission housing:

Pre-tension intermediate shaft to .. ,..... ,........... , 0 .03- 0 .08 mm 0 .0 12-0.0032"

Torques
Bell housing bolts . 35-50 Nm 25- 35 [Link] .
Output shaft flange n ut. . 90--1 l O Nm 65- 80 [Link] .
Rear CQver (gearshift assembly) .. 35-50 Nm 25-35 ft .lbs .

Group 4 3
M anual Transmission 1
Special tools

Special toois. transmission M 4S/M 46

To order, put 999 in front of tool numbet'

1801
2261
2412
Standard handla
Pullar drive flange
Drift, Install/ng Input shaft bearlng
2413 Drift, removlng / lnstalllng rear cover seal
2520 Stand
•
2831 Press tool, Installlng maln shaft bearing
2852 Adapter , Install/ng gear and synchro ring
2853 Adapter . removIng gear and synchro rmg
2867 Drift, Installlng bell housmg seal
2985 Adapter . removmg maln shaft beanng
2986 Drift . Install lng mtermedlate shaft bearings
5058 Tool , removmg maln shaft bearlng
5064 Drift . Install/ng rear cover seal
2261 Pullar
drive flange
•
•
5065 Drift . mstalllng sealon shltt selector rall
5069 Puller removIng rear seal
5111 [Link] drift, Insl allmg clutch
5130 Fixture, auachlng transmiSSion 10 stand 2520
2412
5131 Pullar, removmg mtermedlate shaft bearlng
5147 Tool removmg maln shah beanng .usedwith 5058 V
5148 To~ . removIng mal n shatt bearlng on M 4 6
5149 Wranch removmg / mstalllng flange nut
5177 Pulle, Intermediate shaft bearlng , alumlnum houslng

•
5180 Drift. Inlermedlate shaft bearlng, al umlnum houslng
5181 Pliera . removIng pin on gearshlft lever
5972 Fixture, removIng transmiSSion
2412 Drift
Instanlng Input shaft
bearmg

2413
•
•/

2413 Drift 2520 Stand 2831 Press tool

removlng/lnstalling rear 5130 Fixture mstallmg main shah
cover seal attaching transmiSSion to beanng
stand 2520

•
Group 43
2 M anual Transmission
 Special roats

2852 Adapte,
mSlalllng gear and
.. 2853 Adapter
removing gear and
1801 Standard handla
2867 Drift
synchro nng synchro ring mstallmg bell housmg seal

2985 Adapter 2986 Drift 5064 Drift

removmg maln shaft In51allln9 Intermedlate Installmg rear covar sea!
bearlng shaft bearings
5058 Tool
rernovmg mam shalt
bearmg
5141 Tool
removmg mam shalt
bearmg
5148 Tool
rernovlng maln shaft
beanng . M 46

5065 Drift 5069 Pulla, 511 1 Centering drift

installlng sealon shiit removmg rear seal mstalling clutch
seleetor rall

Group 4 3
M an ual Transmission 3
 Special rools

""Il
5131 Pullor 5149 Wrench 5972 Flxlure
removmg mtermedlate removlng /mstalllng flange removIng transmission
shaft bearing not

5177 Pullor
mtermedlate shah beanng , mtermedlate shaft bearing, removmg pin on gearshlft
alummum housmg alummum houslng lever

Modification offixture 5130

FIxtures dehvered prior to Int roduCllon of 1979- transmiSSion M 45 / M 46 can be modtfled to ht later model
transmiSSions

Dl-,,". 10 1'11\

Drill a hole 10 mm _ 3 / 8 " Aemove

matenai sl ock as shown

' ....
Group 43
4 Manual TransmiSSIon
 Spare parts illustrations

Spare parts illustrations

,
•
.. . .J)

' ...,

Group 43
Manual Transmission 5
SP<U8 parts illustrations

Transmissions M 451 M 46

'No" Descnpuon

·Transm M 45
"'No
17
DescnptlOn

- Drive !Iange 1100

•
· . Drive flange 1300 M 45
· Drive !Iange 1300.
·Transm M 46 M 45
· . Overdnve laycock 115659 18 · Drive !Iange, 1140
M 46
·Transm M 45 - Drive flange 1300
· Drive !Iange 1100 M46
19 · Nut
·Transm M 46 20 · OverdrIve, B 21
.. Engme D 24 Lavcock 115660
2 · Bell housmg, B 21 · Qverdnve, B 271 B 28
. Bell housmg, B 27/B 28 Laycock 1 15659
2. · Bell housmg, D 24 - Qverdnve. D 24
Laycock 115895
3 · -Ball, B 27/B 28 21 -Gasket
3. 'Screw 22 -Clrcllp
3b - ResIlient washer 23 -Gam, 011 pump
3e -Screw M 12xl00 24 . Key
-Screw, M 10x70, D 24 25 'Clrcllp
3e - ResIlient washer 26 · Spnng washer
31 - Screw, M 12x40 27 · Nut
39 -Screw, M 10x40 28 Speedometer gear , M 45
3h -Screw 18 teeth. rear axle 3 54
4 -Sleeve, B 21, D 24 Speedometer drive, M 45
- Sleeve, B 271 B 28 19 teeth , rear axle 3 73
5 ,Clrcllp, B 21, D 24 Speedometer gear , M 45
'Clrcllp, B 271 B 28 20 leeth, rear axle 391
5. o GUide sleeve, D 24 Speedometer gear, M 46
5b 'Washer , D 24 20 teeth, rear axle 456
6 ,Seal 29 Speedometer gear,
6. ,Adapter sleeve, D 24 overdnve
7 ' Gasket 19teeth, rear axle 3 73
8 ' ~Iange screw, M 1Ox40, Speedometer gear,
9 ' Plate "
overdflve
la 'Switch, back-up light 20 teeth, rear axle 3 91

"
12
13
·Washer
·Plug
· Packmg
30
31
32
Bearmg cage
O-nng
Seal
14 · SWitch . overdnve 33 Screw, dnlled for seal
15 ·Plug 34 Lock washer
16 ·Plug 35 TransmissIOn bracke!
36 Gear shdt assembly

Group 43
6 Manual Transmission
 Spare parts i/lUSfraf/ons

SA sa
v (l) lA ,

36)-4

S---G--
, ~'
,

,
,
: ~6A
"
"
'I
'I b\ IL
" ""Ir
\ "

19

S~,

, ,
9
3E

\
..
,II
'

Group 43 7
M anual Transm/ss/on
Spare parts illusrrarions

Transmission parts

II I
No
1
2
3
Oescription

· Houslng .
·-Pm
- - Beanng pm
II I
No
34
Oescriptlon

,Shlm, 0,05 mm ..
,Shlm , O 10mm
-Shim , O 15mm
.'
4 -Input shaft - Shlm , 0,35 mm _ .
5 - Ball bearmg -Shlm , O 50 mm ..
6 - Lock ring . -Shim, O 70 m m ..
7 - Main shaft, M 45 . -Shim , 1 OOmm
8 - Main shaft , M 46 _ 35 - Reverse gear
9 · Needle bearlng 36 - Shalt.
10 - Synchro ring 37 - Selector rail .
11 · Lock rmg 38 - Shiit fo rks
12 · Synchro hub 39 -Dog _ ..
13 -Dog 40 - Shlfter
14 - Lock ring 41 -Tubular pm
15 - Synchro ring 42 -Seal
16 - Sleeve . 43 - Lever
17 - Gear, 3 , rd 44 - Lock ring
18 - Gear, 2 nd 45 -Washer .
19 · Synchro ring . 46 · Seleetor plate assy
20 - Synchro hub 47 · Spring
21 -Dog 48 · Detent ball
22 · Lock rmg 49 · Detent ball spring
23 - Lock rmg 50 · Gasket
24 · Sleeve 51 · Top cover
25 - Synchro rmg 52 " Spring
26 - Gear, 1 st , except D 24 53 ., Screw
- Gear, 1 st , O 24 54 ··Pl ug , 1 / r - 14NPTF
27 -Thrust washer 55 · · Pl ug , M 14)(12
28 - Ball beaflng 56 .. Packmg
29 - Lock ring , M 46 57 · Screw
30 - Sh im , O 60 mm .. 58 · Speedometer drive gear
·Sh im, 0,75 mm M45,B21
· Sh lm, O gO mm · Speedometer drive gear ,
- Sh lm , 1 00 mm M 46
31 -Intermedlate shaft, Overdrive 115659 to
e)(cept D 24 No 3406
- Intermedlate shaft , D 24 Overdrive 115660 to
32 · Roller bearmg , No 24190
except D 24 Overdnve 115895 to
· Roller bearing, D 24 No 12 .
33 · Roller bearmg ,Speedometer drive gear,
M 46 .
Overdrive 1 15659 from
No 3407
Overdflve 115660 from
No 24191
Qverdnve 115B95 from
No . 13
59 - Gasket, .
60 -Cover, rear, M 45
61 -Intermedlate houslng ,
M 45
62 - Flange screw
63 -Seal

Group 43
8 Manual Transmission
 Spare parts illustrations

2nd 1st
gear

,,
~

I 3rt! gear
~
main shatt , M4 5

r
~
\.J...JIlJ....-
n J'main Jll
shaft, M46

int.erned1ate
shaft

<everse
gear

Group 43
Manual Translnlssion 9
 Spare parts Illustra flons

Transmission controls
""
Il! Descnptlon
No
Bracket, B 2 1 29
Bracket. B 271 B 28
Bracke!. D 24
2 Bushing. upper
B21 D24 grey
"
Bushlng,lower, B 21
D 24, light grey
Bushing, black.
B 27/B 28 27
3 Sleeve
4 Washer
5 Screw, M 10x55
6 Gearshlft rod, B 2 1
Gearshdt rod, D 2 4
Gearshdt rod, B 271 B 28
7 · Bushmg
8
9
10
11
12
·O·rlng
P,n
Gearshdt rod jomt
O·rmg
P,n
--- -----"
13 Gearshdt lever IL
Gearshllt lever
14 · Reverse detent knob
15 'Pull rod
'Pull rod
16 · Screw, pull rod
17 · Bushmg upper
18 · Bushmg lower
19 ·Tubular pin 13 --1
20 · Reverse deten! sleeve
substltuted by l7
· Reverse detent sleeve

21 , Screw, early type

substltuted by
'Screw

22 . Ball socket

•
23 . Damper, rubber
24
25
26
27
,Clrcl lp
. Thrust spring
. Cable harness
Rubber bellow
15 -f
28 Gear lever caslng,

•
black leather
Gear lever caslng
beige leather, not coupe
Gear lever caslng,
beige leather. coupe
29 Gear lever knob
30 'Bushlng
31 Gear lever knob
lower sectlon
32 Gear lever knob
upper secllon
33 SWitch overdnve
34 Screw
35 Ball socket
36 Damper, rubber
37 lockmg plate
38 Screw
39 Lockmg screw

12
•

10 12
Group 43
10 Manual TransmiSSion
f"

Spare parts Iflustrattons

r\ I )
4

(y~r' .
Transmission mounts
Engine. B 21 and B 27/ B 28
9
12
12
10

lA
l
o
o
o
,o
o

"'
No
Descnptlon

1 Bracket 8 21
Bracket B 27/8 28
Bracket D 24
2 Bushlng upper :
8 21 O 24 grav ••

~
Bushlng lower . B 21 024 ,
light graV
Bushing. black ,
827 / 828
3 Sleeve
4 Washer
5 Screw M 10)(55
6 Gearshlft rcd B 2 1
Gearshlft rcd D 24
Gearshlh rcd . B 27/ B 28
7 · Bushmg
8 -Q-ring
9 P,n
10 Gearshlft rcd JOlnt
11 O-ring
12 Pm
13 Gearshlh lever
Gearshllt lever
14 · Reverse deten! knob
15 · Pull rcd
· Pull rcd
16 · Screw. pull rcd
17 · Bushlng upper
18 · Bushmg lower
19 · Tubular pin ,II
130451
Group 4 3
M anual Transmission 11
Spare parts illustrations

•
3

Transmission mount
Engine D 24

HI Descnptlon
No
1
2
3
4
5 cushion
Rubber cushion
6 Washer
7 Nut

' ...., •
Group 43
12 Manual Transmission
 Design andfunction

Svnchronization

Neutrel position Synchronizing Gear engeged

1 Gear teeth l Synehro ring

2 Synchro ring 2 Synchro sleeve
3 Synchro sleeve
A and B are forees eaused by the different speeds of the gear
4 Dags (in siats)
and the synchro ring.
5 Synchro hub
6 Spring e is the force from the synchro sleeve shift fork.

When engaging a gear, a shift fork moves the synchro Because the synchro dags press the synehro ring on
sleeve (3) towards the gear teeth /,). The synchro dogs the gear cone, frictian results between the two surfaces.
(4) move with the synchro sleeve and will thus press the This ffiction will slow the speed of the gear to be the
synchro ring against the eone on the gear. If the synchro same as the synchro sleeve. With both turning at the
sleeve and the gear have different speeds, the synchro same speed, the synehro sleeve can then turn the syn-
ring will turn in relation to the synchro sleeve. The chro ring halt a tooth backwards. The synchro sleeve
synchro dags, however, prevent the synehro ring from can then slide over the synchro ring and engage the
turning more than half a tooth w idth. gear teeth .
The synchro ring will then be halt a tooth out of align-
ment with the synchro sleeve. This will prevent the
synchro sleeve from sliding over the synehro ring and
engaging with the gear teeth.

Power flow through the transmission

11111 11 713
First ge.r SeeoAd gear Third gear

2111~

Fourth geer Revers. gear

Group 43
Manual Transmission 13
M 45/M 46 Features

New features of
M 4S/M 46 transmission 1979-

.,

Transmission housing contains one shift selector rail

(previously 3) .

Spring on transmiSSion cover keeps reverse shift

selector In position, Three stop lugs for selector
plates are also included on cover
Recess for one shlft selector ra il has been removed.
making cover flatter

•
Group 43
14 Manual Transmission
 M 45 / M 46 Features

' ------- f ' ; )

, '1\\
I' Input shaft
,\ The mput shalt has 22 spi mes (prevlously 10)
Clutch dlsc IS changed to accomrnodate the new
shaft

N,w

4-cyl and 6-cyl modals with manual

transmission

Centering drift for new clutch plate

CentermQ dflft 999 5111 IS requlred for centeflng
the clutch plate on the new M 45 / M 46 transmIS-
Sion

511

Gear

Flal'lge

• •

Gear-change controls
The gear-change controls cons,st of gear selector rall ,
gear selector, two (shltt) forks, f lange and selector
plates
Gear selector rail IS loca ted In t ransmiSSion houslng
Shltt torks move on gear seleetor rail The !Iange also
SitS on the gear selector rail but is hel d In position by
a pin

torka

Selector fllIl

Group 43
Manual Transmission 15
M 45/M 45 Features

The transmiSSion has two seleetor plates which are

controlled by three gUides In the transmission hous-
mg They are held In position by the return spnng
and transmiSSion cover

plates spnng
•

•
The seleetor plates contain siats m whlch the flange.
shlft torks and reverse gear selector run

,,., ...

Seleetor plates are deSigned so that both plates are

actuated by the tiange and move Sldeways

"''''

Group 43
•
16 Manual Transmission
 M 45/M 46 Features

When the gear lever is moved forward or rearward

the Ilange actuates only the lower (small) plate
whlch moves rearward and forward .
Gear-changing movement IS transmitted (as descri-
bed above) to the shiit lork or gear selector (reverse)
which engage the deslred gear.

,,' ..
Synchronizing parts
Sharp points are mach in ed into the teeth on third
and lourth gears.
/ \
"'-- ~

The recesses in the synchronizing rings are narfQW to

lacihtate changing gears

Shift forks
The shift torks are made of steel and have loose brass
lugs

10
."

Group 4 3
M anual Transmission 17
M 45/M 46 Features

•
Gear lever
The bonom secuon of the gear lever (ball end) IS a
one plece design (Prevlously the parts were welded
together.) This change allows the pull rod lO operale

•
on the outsIde (prevlously inside)
-Ion ger Interlock sleeve prevents jamming
- wlder diameter ball
- ball locatmg spring IS replaced by two rubber
dampers

•
'" "'"

•
- Reverse slot IS on lelt si de 01 lever instead of the
rear

Gear lever carrier

The carner con51sts of a rectangular tube and braeket
welded togeIher Four bolts secure the carner to the
transmiSSion houslng (These same bolts secure the
transmiSSion rear cover )

•
Group 43
18 Manual TransmiSSion
 M 45/ M 46 Features

,
I Oil change
Another interestlng new feature is the exclusion 01 oil
change every 30 ,000 mi The oil is changed on ly In
connection with the warranty service
The 011 level IS subsequently checked at the ordinary
servlclng

6-eyl gas models

Gear lever cover

New gear lever cover In black leather on all 6 -cylinder
models with manual transmiSSion

",,'"

Manual transmission.

Manual transmissions have been equipped with needle

bearings for lirst, second and third gear.
This doas nol affecl the repair melhods for manual
transmission.

Group 43
Manual Transmission 19
M 4 5: replacing rear seal in vehicle

M 45: replacing rear seal in vehicle

Spec ial 10015:

2261 Pulla" drive flange 5069 Pullar, removing rear seal
5064 Drift, installmg rear cover seal 5149 Wranc h , removmg/mstallmg flange nu!

Removing seal - - - - - - - - - - - - -

Disconnect propeller shaft from

Al

•
transmission .

Remove 'lange nut.

A2

•
Usewrench 5149 and socket '27 mm ... 1- 1 / 16" .

A3

Remove flange.
Use puller 2261

•
Group 4 3
20 Manual Transmission
 M 45: replacing rear seal in vehicle

A4

Remove seal .
Use pull er 5069

I
Installing seal - - - - - - - - - - - - - -
\ A5

Install new seal.

Use drift 5064.

I A6

Install flange.
Use wrench 5149 and sockel 27 mm _ 1- 1 /16"
Torque 10 9~110 Nm .. 65-80 [Link]

A7

Attach propeller shaft to flange.

Group 4 3
M anual Transmission 21
M 4S /M 46: replacing back-up light switch in vehicle

AB

Check oillevel.
Use Automatic Transmission Fluid type F or G
•

M 45/M 46: replacing back-up light switch in vehicle

BI
-~~ I ,:--A

=l
~
Disconnect gearshift lever cover.

===r .. ~~"-'=. ... ~

B2

Disconnect connector.
To gain access. remove left side panel of center con·
sole

•
Group 43
22 Manual Transmission
 M 4S / M 46 replacing back-up light switch in vehicle

83

"">'~--
I approx. 4 O cm
C16" ) ~,

Bend a steel wire to shape as shown.

(early)

84

Position steel wire.

Insert the bent steel wire between floor msulatlon
(ind transmission tunnel on right side

85
Gain access to back-up light switch.
Ralse vehlcle on hOI st
[Link]).

86
Replace back-up light switch.

(as applicable)
Use wrench 22 mm = 7/8" to replace back-up light
switch.

87
Re-clamp wire to gearshift carrier rod.

88
Place harness on steel wire as shown.

89
Install cross member bolts. Lower vehicle.

Group 43
Manual Transm ission 23
M 45/ M 4 6 replacing back-up light switch in vehicle

BIO

... Inside vehicle:

Pull wiring harness
light
Attach connector for back-up

~ ai J=r~- Bli

Check operation.

n ...

B12

Installleft side panel center console.

B13

Install gearshift lever cover.

..
'

•
Group 4 3
24 Manual Transmission
 Repa/res ro gearshift lever in vehicle

M 451 M 46: repairs to gearshift lever in vehicle

O M
45
These repalrs reler partlcularly to replacmg reverse
detent sleeve and/or reverse pull rod

l
From mld-79 there IS a new type reverse detent
sleeve on the gearshdt lever It has a gUide whlch
prevents It Irom rotating on the gearshlft lever and
eKerting forces on the reverse pull rod It also hes a

I
slot whlch gUides reverse pull rod, preventing It Irom
rubbmg the detent plate

(!:)
SPACER WAS HER

12)2(017 - 2

new

REVERSE PULL ROD

In case the reverse pull rod breaks, the old type re-
verse detent sleeve should also be replaced It IS
2 mm _ O OS" longer than the old one Therelore ,
the gearshllt lever knob should be ralsed accordlngly
to permit Iree travel of the reverse detent sleeve

I This IS done by mstalllng a 2 mm - OaS" thlck

spacer washer with d,smeter 13 mm - approx

:O
1/2" mSlde the gearshllt lever knob
The retalnlng screw for the reverse detent sleeve
should also be replaced The new type screw is case
hardened
SLEEVE Atter mod,l,callon, check gearshdt operation
/ DETENT
/' StREW
....

DE TENT PLA TE

.~
.'
Group 43
Manual Transmission 25
Repairs to gearshifr lever In vehlc1e

CI

Disconnect gearshift lever cover.

Remove four clipS retslnlng cover lift up cover slong
gearshlft lever
Be careful, not to damage electncal wires There IS no
need to dlsconnect wires
•
}>
\
C2 •

Remove lock pin. •

Usa punch

.-
C3 Ife
M 46 :
Un-pl ug connector for overdnve wire

C4
•
M 46:
Remove top of knob.

•
Group 43
26 Manual TransmiSSion
 Repalrs ro ge8rshih lever in vehicle

C5

Lift up gearshift lever.

C6

Remove gearshift lever knob.

POSition gearshlft lever m a Vise wllh soh taws
Use plaslic mallet to carefully knock off knob .

C7

Remove detent knob.

Remove screw l ift off delenl knob

ca

Remove pull rod.

Remove pull rod, sprmg and delent sleeve assembly

Group 4 3
Manual Tr8nsmlsslon 27
Repalrs ro gearshlfr lever In vehicle

C9

Remova datent sleeva.

Remove screw on reverse gear delenl sleeve

•
CIO

Use new type detant sleeva.

Reverse delent sleeve , P/ N 1232 687· 1, should be
used

CII

OM45 ,

M46
Spacar was her in knob.
When subsllluling new Iype delenl sleeve for older
Iype, gearshift knob must be ralsed to permit free
travel for delent sleeve
Install 2 mm_ 008 " thlck and 13 mm _ appro){
If.
1/2" diameter spacer washer In knob

-- SPACER WASHER ~

CI2

Band pull rod and.

Bend out pull rod end appro){ 20° This will prevent
rattle

CI3

Install spring and new ravarsa datant

sleeva

•
Apply a drop of locklng fluid (Volvo P/N 277 916·3)
on screw for pull rod Attach pull rod to detent
sleeve

Group 43
28 Manual Transmission
 Repairs to gearshdr lever in vehlcle

C14

Install detent knob.

Grease new pull rod Use screw to Install detent knob
on new pull rod lnstall detent knob and pull rod
assembly on gearshlft lever

C1S

Install gearshift lever knob.

Position gearshlft lever in vise with soft laws.
Use plastlc mallet to carelully knock knob mto
position

C16

Assemble gearshift lever.

Install upper part 01 gearshllt lever on lower part In
vehlcle
Instal11ock pin

C17

Check reverse detent for correct operation.

Engage tlrst gear Dlstance between detent plate and
detent screw should be O 5-1 5 mm -
002-006 ·· AdlUSI by movmg detent plate
Also engage second gear and recheck dlstance

Group 43
Manual Transmission 29
Repairs to gearshift lever in vehicle

CIB

M46:
.'- Connect wire and install top of knob.
,
,
/'
/

''''11
CI 9 •
M 46:
Install connector for overdrive wire.

C20
•
Install gearshih lever cover.

Group 4 3
30 M anual TransmIssion
 M 4 5, removal

Removing transmission M 45

Special toois :
5151 Flxlure
5181 Plien;

DI

I
.;>
Disconnect battery ground cable .

'-II

From under vehicle: 02

Disconnect gearshift lever from gearshift

rod.
Remove lock bolt Usa pIIers 5181 to remove pIVot
p,n

Inside vehicle: 03

Disconnect gearshift lever cover from floor.

Group 4 3
Manual Transmission 31
M 45, removal

04

Inside vehicle:
~ Remove lelt side panel of center console
- Dlsconnect connector for back-up hght

05

•
Remove reverse detent plate ,
•
06

•
Remove gearshift lever.
Remove lock ring to remove gearshlft lever

07
•
Remove plastic bushing and rubbar ring.

•
Group 43
32 Manual TransmiSSion
 M 45, removal

From under vehicle: 08

Unhook clutch fork return spring.

09

Remove cross·member assembly

Cross-member includlng rubber cushlon and bracket

010

Disconnect:
- Speedometer cable from drive gear
- Propeller shaft Irom drive Ilange
- Clutch cable horn lork and bell housmg

011
Remove front exhaust pipa attachment.
Remove bolts at bell housmg
Remove nut at exhaust pipeS

0 12

Unhook rubber supports for front muffler .

013

Regin separating bell housing from engine.

Remove all bollS except two at bonom

014

Pull out starter motor undl free from bell

housing.

Group 4 3
Manual Transmission 33
M 45, remo.",al

075

Position transmission fixture.

Secure transmission rigidly on fixture_

076

Remove two lower bolts at bell housing.

077 •

RemoV8 transmission.
Tum transmiSSion to free It from propeller shah tun-
nel white pulling towards rear

•
Group 43
34 Manual Transmission
 M 45, dlssassembly

Disassembling transmission M 45
Special toois:

2261 Puller drive Ilange 5131 Pullar removIng Inlermedlate shah bearlng
2413 Drift removlng/mstallmg rear cover seal 5147 TooI, removIng maln shaft beanng. used
2520 Stand with 5085
2853 Adapter, removIng gear and synchro rmg 5149 Wrench removlng/mstalling flange nut
2985 Adapter , removIng maln shaft beanng 5177 Pullar , mtermedlate shaft beanng
5058 Tool , removIng maln shaft beanng
5130 Fixtura attachlng transmisSion to stand
2520

E7

Attach fixture 5130.

Use four bolts to attach to stand 2520
NOTE:
Moddled type flllture 5130 must be used See
'"Modiflcatlon 01 lixture 5130" at end of Special
T001 sectlon

E2

Install transmission fixture.

Ensure all matlng surfaces align when tightening
hoiding boh

E3

Remove sound deadening material from

gearshift carrier.

E4

Remove drain plug and drain oU.

Group 43
Manual Transmission 35
M 45, dlssassembly

E5

Remove:
- Back-up light switch
- T ransrrHSSlon top cover

E6

Remove:
- Spring and detent ball
- Selector plate assembly and return spring
- Gasket

E7

Remove:
Gllde washers lor selector plate assembly
- l ock pin lor shlher

EB

Remove:
- Selector rail
- Shlher and shlh torks

I •
Group 43
36 Manual Transmission
 M 45, dlssassembfy

E9

Remove gearshift carrier assembly.

E10

Remove drive fl8nge nut.

Socket 27 mm _ 1-1/ 16" Use wrench 5149 to
hold

__ E11

2261

(
Pull off drive flange.
Puller 2261

E12

Remove speed om eter driven gear.

Remove bolt and retalner 10 pull out gear

E13

Remove rear cover.

Remove gasket and shlms

Group 43
Manual Transmission 37
M 45, dlssassembJy

E7 4

Remove speedometer drive gear.

El5

Remove main shaft bearing.

POSlllon adapter 2985 between input shaft and front
synchro nng Remove beanng spacer ring Use tools
5058 and 5147 to pull oH bearing
Remove thrust washer

Remove clutch fork.

E76
r
Save spacer washer and throw-out beanng

E77

Remove bell housing.

Remove gasket and shlms InhelC wrench 8 mm

E78
east iron housing:

Remove outer races for intermediate shah

bearings.
FHSt knock Intermedlate shaft back untll rear race IS
tree
Then knock Intermedlate shah forward until front
outer race can be removed

Group 43
38 Manual Transmission
 M 4 5, dlssassem bly

EIB
Aluminum housing:

Remove outer races for intermediate shaft

bearings
Carefully knock Intermedlate shalt untd pu\\er 5177
can grip races

EI 9

Pull out input shaft.

E20

Remove 4th gear synchro ring

E2 1

Lift out main shaft.

E22

Lift out intermediate shaft.

Group 43
M an ual TransmISSIon 39
M 45, dlssassembly

E23

Remove reverse gear and shaft.

Use punch 10 knock shah back

E24

Remove reverse gear shift fork.

E25

Ramove seal for salector rail.

E26

31
Ramova intermediate shaft baarings.

.. Use puller 5131

••
Group 43
40 Manual Transmission
 M 45, dlssassembly

E27

Remove 1 st gear and synchro ring from

main shaft.

'I''''
E28

Remove lock ring for 1-2 synchro hub.

' ....
E29

Press off synchro hub and gear.

NOTE Can be tight so a press may be needed
Use adapter 2853 .

E30

Remove lock ring for 3--4 synchro hub.

Group 43
Manual Transmission 41
M 45, dlssassembly

E3 '

Press off synchro hub and gear.

NQTE Can be tight so a press may be needed
Use adapter 2853

E32

Ramova lock ring and spacer ring for input

shaft bearing.

2853
Remove input shaft bearing .
NOTE Can be tight so a press may be needed
Use adapter 2853, small hol e UP under bearlng

E34

Ramove sleava on gaarshift rod joint.

Group 43
42 Manual Transmission
 ,
M 45, dissassembly

E35

Disassemble gear selactor mil and gearshift

rod.
Use a 5 mm punch to push out front pin

E36

Remove gearshift rod bushings.

E37

- Remove bell housing seal .

• E38
•
2413

• / Remove rear cover seal .

- Use dnft 2413 to knock out seal

Group 43
Manual Transmission 43
M 45, dlssassembly

E39

Oisconnect two synchro hubs.

Push hubs out 01 sleeves

E40

Cleaning.
Clean all parts In solvent Blow dean wIth compres-
sed air

E41
Checking .
Carelully check all parts Replace worn or damaged
parts Replace gaskets and seals

New features of
M 45/M 46 transmission 1979-

Manual transmission.

Manualtransmisslons have been equipped with needle

bearings lor lirst. second and !hird gear.
This does not affect the repair methods lor manual
transmission.

Group 43
44 Manual Transmission
 M 45, assembly

Assembling transmission M 45
Special toois:
1801 Standard handla 5065 Drift, mstalhng sealon shiit selector rall
2412 Drift, Instalhng mput shaft beaflng 5149 Wrench, removmg/instalhng drive flange
2831 Pr8$S tool , installmg mam shalt beanng nut
2852 Adaptar, mstallmg gear and synchro ring 5117 Pullor, intermedlate shalt beanngs, aluml-
2861 Drift mstallmg bell houslng seal num housmg
2986 Drift , Instalhng Intermedlate shalt bearmgs 5180 Drift, intermedlate shaft beanngs, alummum
5064 Drift , Installing rear cover seal housmg

Fl

Connect 1-2 and 3-4 synchro hubs.

POSlllon hub m sleeve so that hub slots ahgn
I
chamlered teeth In sleeve. Insert dogs (three) and
lock them with springs
NQTE With curved lock ring , ahgn sprmgs 10 let tree
ends press agamSI synchro ring

F2

5064

/ Install rear cover seat

Use drift 5064

F3

Install ball housing seal.

2867 Use drift 2867 and standard hand le 1801

-
Group 43
Manual Transmission 45
M 4 5, assembly

F4

Install seal for selector rall .

Dnft 5065

F5

Position rubber ring in joint.

".

Connect gear selector rail and gearshift rod.

F6
1
Selector rall grooves UP

Fl
Install sleeve on joint.

ro
Install bushings on gearshift rod.

... Use grease to retain rubber nng on one side

F9

Install:
- 3rd gear and synchro ring
- 3- 4 synchro hubs on maln shah
-lock ring
2852 Use adapter 2852 when pressIng on gear and hub

Group 43
46 Manual Transmission
 M 45, assembly

F/O

Install:
- 2nd gear and synchro hub
- 1- 2 synchro hub on maln shaft
- Lock ring
Use adapter 2852 when pressmg on gear and hub

'*
Fil

Install1st gear and synchro ring on main

shaft.

F/2

Install two intermediate shaft bearings.

Use drift 2986 to press on bearlngs
NOTE Intermediate shaft small end bearmg IS
different for diesel applicatlons
Use correct type bearmg

F/3

Install bearing on input shaft.

Use dnft 2412 to press on bearlng

Group 43
Manual Transm ission 47
M 4 5, assembly

FI4

Installlock ring on input shaft.

NOTE DO NOT Insta ll spacer ring on beaflng at this
time
It will be Installed later on

_____ Special instructions for transmission with aluminum housing - - - - -

Prior to further assembly. Intermedlate shalt pre-

tenSion should be determined Follow operations
F15- F24

FI5

Position intermediate shaft in housing .

F/6

Position outer races for intermediate shaft

bearings.
Use dnft 5180, large outer diameter toward race

Fl

Install bell housing with gaskat.

Torque bollS to
35-50 Nm - 25-35 ft .lbs

Group 4 3
48 Manual Transmission
 M 45, assembly

FI8
Turn transmission to vertical position.

FI9

Eliminate clearance in intennadiate shah

bearings.
Use dnft 5180. small diameter toward rear race .
Hold drift rigldly and knock in face with light taps
5180
Repeat whlle rotating shaft . untll all clearance IS gone
and shaft runs somewhat slugglsh

F20

Measure distance between intennediate

shaft bearing outer race and rear surface of
housing.
Use depth gauge and note readmg

- F21

Determine thickness of shims for

intermediate shah.
Shalt pre·tenSlon should be O 03-0 08 mm Gasket
thlckness O 25 mm (melnc only) ,

E:o:ample
Dlstance. race-surface 1 51
Gasket +025
1 76 1 76
Pre·tenSlon +003 to +008
Shlm thlckness 1 79 lo 1 84
Choose 1.80 mm shlm thlckness
Shims avallable O 05 mm
0.10 mm
0, 15 mm
035mm
050mm
070mm
1.00 mm

Group 43
Manual Transmission 49
M 45. assembly

Remove bell housing and gaskat.

F23

Ramove outer races for intermediate shaft

bearings.
Caretully knock mtermedlate shall In untll puller
5177 can grip races

F24

Uft out intermediate shaft.

---End of special instruetions for transmissions with aluminum housing ___

Contlnue assembly, using same operations as fo r

transmission with east Iron housmg
Exception
- Outer races tor Intermedlate shaft bearlngs are
Installed as descflbed above
- Shim thlckness IS determmed

F25

Install reverse goar shifter.

Installlock ring

Group 43
50 Manual Transmission
 M 45. assembly

F26

Install reverse gear and shaft.

F27

Cheek and adjust reverse gear shatt

position .
Shah end should be minimum O 05 mm - 0002 "
under housmg face

F28
Important!

Adjust clearanee between reverse gear and

shift fork.
Correct clearance IS O 1- 1 O mm _ O 004-0 04"
AdJust by knocking shih fork pivot pin aXIally w ith a
punch

,., F29

Position intermediate shatt in housing.

.. Position on bottom of housmg

..
'

Group 43
Manual Transm issIon 51
M 45, assembly

F30

Position main shaft in housing ,

F31

Position thrust washer and bearing on main

shaft.
Beaflng should be IIned with posltlonmg nng

F32

Press main shaft bearing into position.

Use press tool 2831
Press reverse gear toward transmisSion center Check
that no gears comclde and become damaged

.
... ~-
F33

..
Use spacer for tool if bearing does not align
correctly.
Spacer should be posltloned between tool spmdle
and housmg front end Beaflng posltlonmg flng
should be flush with houslng face when beanng IS
correctly posltloned

Group 43
52 Manual Transmission
 M 45, assembly

F34

Gr. . . . . nd install input shaft roller bearing .

F35

Position 4th gear synchro ring in synchro

hub.

/ Attach input shaft to main shaft.

Push shaft in all the way

F37

Lift up intermediate shaft.

POSition shah so beanngs are correctly positloned 10
houslOg

F38
Pull out input shaft so that spacer ring can
be positioned on bearing.
Then push 10 shaft aga lo Spacer nng should Ile
agalOst houslOg

F39
east iron housing:

Install intermediate shaft outer bearing

races.

Group 43
Manual Transmission 53
M 45. assembly

F40
Aluminum housing:

Install intermediate shaft outer bearing

races.
Use dnft 5180, large outer diameter toward hearmg
races

F47

Measure distance between front end of

input shaft bearing and housing front
surface .
Use depth gauge Note reading (metric)

F42

Measure distance between bell housing

surface and bearing seat bottom.
Use depth gauge Note readi ng (metnc)

F43

Determine shim thickness for input shaft.

AX ial clearance permitted 0 .0 1-020 mm NQTE
gasket thlckness O 25 mm must also be conSIdered
Use melne measuremenlS only
See example next page

Group 4 3
54 Manual Transmission
 M 45, assembly

Example
Dlstance. flywheel houslng
to bearmg bonom 560
Gasket thlckness +025

575
Distance. beanng to
housmg - 471

l 04 l 04
Clearance permlued -O Oho -0_15
Shim thlckness, mm 1 03 to 089
Choose shlm O 90 mm
Shlms avaliable O 60 mm
O 75 mm
090mm
100mm

F44

Attach bell housing.

Use grease on gasket and shlm to keep in place
Torque 35-50 Nm _ 25-351t Ibs

F45
Aluminum housing:
Install clutch fork.
Includmg spacer

F46

Install throw-out bearing.

F47
Aluminum housing:

Turn transmission to venical position.

Make sure intermediate shaft bearings
have no clearance.
Use drift 5180 With small diameter toward rear bear-
mg race Hold tool ngldly and knock on race with
light knocks Repeat while roIating shalt untll all
clearance IS gone and shaft runs somewhat sluggish .

Group 43
Manual Transmission 55
 F
M 45. assembJy

F48
east iron housing:

Tum transmission vertical position .

Measure distanee between intennediate
shaft bearing outer raee and rear surface of
housing .
Race should bult rollers Use depth gauge Note

-.. readmg (metne)

F49

Determine thickness of shims for

intermediate shaft.
Ä)(ial clearance permllted 0025-010 mm Gasket
thlckness O 25 Metnc ont y

Example:
Dlstance. race to surface 1 43
Gasket +025

1 680 1 680
Ctearance permItted -O 025 to O 100

Shlm thlckness 1 655 to 1 580

Choose 1 65 mm (ah 1 60 mm)
Shlms avadable O 05 mm
O 10mm
O 15mm
035mm
050mm
070mm
1 00 mm

F50

.. Measure distanc8 between front of main

shatt bearing and housing rear surface .
Use depth gauge Note readmg (metnc)

'.-
Group 43
56 Manual Transmission
 M 45, assembly

F5J

Measure distanee between rear eover

surface and bearing seat bottom.
Use depth gauge Nate reading (metric)

F52

Determine shim thickness for main shaft.

AXial clearance permlued 00 1-020 mm Gaskat
thlckness O 25 mm

Example:
Dlstance. cover to
bearing bottom 550
Gasket +025

DIstance, beanng to
housing - 471

104
Clearance permitted -001 to -020

Shim thlckness 103to 084

Choose sh im O 90 mm
Shlms available O 60 mm
O 75mm
090mm
100mm

F53

Install speedometer drive gear. gasket and

shim pack for intermediate shaft.
Speeda meter gear flange toward beanng
Shlm pack determlned
- Op F 15-F24 for transmiSSIOS With alummum
housmg
- Op F48--F49 for transmisSions with east Iron
housing

Group 43
Manual Transmissio n 57
 M 45, assembly

F54

Position shim for main shaft in rear cover.

Apply grease to shlm lO keep 11m place.

F55

I
Install rear cover.
Install twa auler (Iower) bolts finger tight.
InstaJl seal in rear rover using drift 5064.

F56

Install drive flange

Use wrench 5149 to hold
Torque nu! to 90-110 Nm .. 65-80 fl Ibs

5149
•
•••

- - F57

Install speedometer driven gear with O-ring

Group 43
58 Manual Transmission
 M 4 5, assembly

F58
Install gearshih carrier.
Note sequence: bolt - washer - spacer - washer
Torque bolts to :
35-50 Nm -= 25-35 ft,lbs

F59

Install two inner (Iower) bolts for rear

cover.
Torque four lower bolts to
35-50 Nm - 25-351t,lbs

F60

Install shift forks.

Make sure lugs position correctly

F61

Install shifter and gear selector rail .

Shiiter boss forward

F62

Install :
- Lock pm for shiiter
- Gllde washers for selector plate assembly

-- •
F63

Install selector plate assembly and return

spring.

Group 4 3
Manual Transmission 59
M 45, assembly

F64

Check operation.
Install gearshdt lever wIthout lock screw and lock
ring
Hold selector plate assembly With palm Check gear·
shiit operation and correct as necessary
Remove gearshdt lever

F65

Install :
- Detent ball and spnng
- New top cover gasket

F66

Install:
- Top cover Torque bolts to
15-25Nm _11_18ftlbs
- Back·up light sWitch
- Sound deadenmg maIenaI on gearshl" carrier

F67
FiII oil.
Lower transmission rear end FIII 0 .75 liter _ 08
US qt 01 Automatlc Transmission FlUid. F or G

F68

InstalIIevei plug.

Group 43
60 Manual TransmiSSIon
 M 45, Instaflation

Installing transmission M 45
Specl.1 tool.:
5972 Fixtur.

Gl

Position transmission and fixture 5972

assembly on lifting deviee .
FIxture m IronI paSlllon to secure
transmiSSion ngldly on fixture

G2

Install transmission.
Check that throw'OUI bearmg IS conectly posllloned
In tork
Ralse IransmissIon Turn transmiSSion to tree II from
propeller shaft tunnel when pushlng II m from rear
Install two lower bolts al bell houslng
Remove 'Ixture and hhmg devlce

G3

Install:
Starter motor and ughten retammg bolts
- Front e)(haust plpe bracket Two bolts at bell
housing, one nut at e)(haust plpe
- Remalnmg bolts for bell houslng
- Rubber rings for front muHler

Group 43
M anual Transmission 61
M 4 5, installation

G4

Install :
- Clutch cable to bell housmg and clutch tork.
- Propeller shaft to transmission dnve flange .
- Speedometer cable

Install:
- Cross-member with rubber cushion and bracket.
- Clutch tork return spring

G6

Inside vehicle:
Install rubbar ring and plastic bushing.

G7

Check that sound deadening material is

correctly positioned.

Group 4 3
62 M anual Transmission
 M 45, installation

GB

Install gearshift lever.

Install retammg nng

From under vehicle: G9

Attach gearshift rod to gearshift lever.

Push pivot pm onto position and mstall locklng
screw

GID

Install reverse detent plate.

Gli

Adjust clearance for reverse gear detent.

Engage 1st gear and adJust clearance between delent
plate and gear shlf! lever
Correct cleraance 0 .5-1 .5 mm _ 0020---0 060"
Engage 2nd gear and recheck clearance

'.0

Group 43
Manual TransmIssion 63
M 4 5, installation

G12

Install connector for back-up light.

G13

Installleft side panel of center console.

G14

Install gearshift lever cover.

G15

Reconnect banery ground cable.

130015

New features of M 45/M 46 transmission 1979-

Manual [Link].

Manual transmissions have been equipped with needle

bearings for first, second and third gear.
This does nol atfect the repair methods for manual
transmission.

Group 43
64 Manual Transmission
 M 4 6, removal

Removing transmission M 46
Special toois:
5972 Fixture, removmg transmission
5181 [Link], removmg pm on gearshlh lever

HI
Important!

Release overdrive.
- Ralse rear wheels from ground
Start engme and engage 4th gear
- Engage overdr,ve
- Depress clutch pedal and stop engme

I
I,
H2

Diseonnect battery ground eable.

l lOO1S

H3
From under vehicle:

Disconnect gearshift lever from gearshift

rod .
Remove lock boll Use pIIers 5181 to remove plVOI
pm

Inside vehicle: H4

Disconnect gearshift lever cover from floor.

Group 43
Manual Transmission 65
M 46, removal

H5

Inside vehicl&:
- RemO\le leh side panel at center console
Separate connector

Separate connector for overdrive .

Remo\le right side panel at center console
Separate both connectors

H7

Remove red and yellow wire from

connector.

Remove reverse detent plate.

Group 43
66 Manual Transmission
 M 46, removal

H9

Remove gearshift laver.

Remove lock ring to free gearshlft lever

HIO

Ramova plastic bushing and rubbar ring.

HII
From under vahicle:

- OlsconneCI speedomeler cable from drive gear

- Olsconnect propeller shah from drive !lange

HI

Ramova cross-mambar assambly.

Group 43
Manual TransmiSSion 67
M 46, removal

As appropriate:
HI3

Clutch controI.

"
Unhook return spring and dlsconnect clutch cable

HI4

Ramova brackat for rubbar cushion.

Remova from axhaust pipa attachment.

Remove bolts at bell housmg Remove nut at eKhaust
pipeS

HIB

Unhook rubber rings for front muffler .

HI7

Begin separating bell housing from engine.

HIB

Pull out starter motor until free from bell

housing.

Ramove transmission.
- POSitIOn fIxture 5972. attached to hfung devlce,
under transmiSSion FIKture m rear poSitIOn
Tlghten attachment bolts to hold transmission
flgldly
- Remove two lower bolts at 0011 houslng
- lower transmiSSIOn Turn transmiSSion to frea It
Irom propeller shalt tunnel whlle pulling il rear·
ward

Group 43
68 Manual TransmissIon
 M 4 6, disassembfy

Disassembling transmission M 46
Special toois:
2520 Stand 5131 Pullar removmg mlermedlate shah bearing
2853 Adaptet. removIng gear and synchro nng 5147 Tool removmg mam shah beanng
2985 Adaptet removm9 mam shah beanng 5148 Tool, removm9 mam shah bearing
5058 Toot removmg mam shah beanng 5177 Pullar, mtermedlate shalt beanngs, aluml-
5130 Fixture for transrrnsslOn num houslng

I l

Attach fixture 5130_

Use four bolts to attach to stand 2520
NOTE
Modlfled type flxlure 5130 must be used See
" ModlhcatlOn of fixture 5 130 at end of Special
Tool sectlon

12

Install transmission to fixutre_

Make sure all matlng surfaces align when tightening
hoiding bolt

Remove sound deadening material from

gearshift carrier _

14

Remove drain plug and drain oil.

Group 43
M anual Transmission 69
M 46. dlsassembly

15

- Dlsconnect wires at overdnve solenOld

- Remove back-up light SWitch
- Remove overdrive SWitch
- Remove transmiSSion top CQver

[6

- Remove detent ball and spnng

- Remove selector plate assembly and return spnng
- Remove gasket

17

- Remove glide washers for selector plate assembly

- Remove lock pm for shiiter

18

- Remove nuts retaming overdrn/e to mtermediate

flange
- Remove overdnve

Group 43
70 Manual TransmiSSion
 M 46, disassembly

19

Remove gearshift carrier assembly.

Remove.
- Remove sleeve for gearshlft rod JOIOI
- Remove gearshlh rcd
Flrst knock out rear pm Then turn rod and knock
out Iront pm

11

Remove intermediata housing.

Remove gasket and shlms

l 12

- Remove gear seleclor rall

- Rernove sh.h er and shlh forks

•
Group 4 3
Manual TransmissIon 71
M 46, d1sassembly

I 13

Rentove overdrive oil pump eccentric.

Remove lock flng and pull off eccentric. Catch key

Remove lock ring and spacer ring for main

shaft bearing.

I 15

Remove main shaft bearing.

Position adapter 2985 between mput shaft and front
synchro nng
Remove beaf/ng spacer nng
Usa tool 5085 + 5148 (2) and 5147 to remove
bearmg Remove beanng thrust washer let adapter
2985 remaln m place

16

Remove bell housing.

Remove clulch tork Catch spacer washer and throw-
outbeanng
Remove bell houslng , using 8 mm inhex wrench
Remove gasket and shlms

Group 43
72 Manual Transmission
 M 46, dlsassembly

117
east iron housing:

Remoye outer races for intermediete shaft

bearings.
First knock mtermedlate shaft back unlil rear OUler
race comes Iree Then knock shalt forward unlll front
ouler race can be removed

I 18
Aluminum housing:

Remoye outer races for intermediate shaft

bearings.
Carefully knock inlermedmle shaft until puller 5177
can grip races

I 19

Pull out input shaft.

120

Remoye 4th gear synchro ring.

121

lift out main shaft

Group 43
Manual Transmission 73
M 46, dlSBssembly

I 22

lift out intermediate shaft.

123

Remove reverse gear and shaft.

Use punch to knock shah back

r 24

Remove reverse gear shift fork.

Remove seal for seleetor reil .

..
-

Group 43
74 Manual TransmissIon
 M 46, disassembly

T 26

Romovo intermediate shaft bearings.

Use puller 5131

' ."
127

Romovo 1 st goar and synchro ring from

main shaft.

"''''
T 28

Remove lock ring for 1-2 synchro hub.

,"-
129

Pross off synchro hub and goar.

NOTE Can be tight so a press may be needed
Use adapter 2853

Group 4 3
M anual Transmission 75
M 46. dlsassembly

130

Remove lock ring for 3-4 synchro hub.

r 31

Press off synchro hub and gear.

NQTE Can be tight so a press may be used
2853 Use adapter 2853

I32

Remove lock ring and spacer ring for input

shaft bearing.

133

Remove input shaft bearing.

NQTE Can be light SO a press may be needed
Use adapter 2853 . small hole UP under bearing

Group 43
76 Manual TransmiSSIon
 M 46, disassembly

134

Remove rubber ring from gearshift rod

joint .

-- 135

Remove gearshift rod bushings.

136

Remove bell housing seal .

137
Disconnect two synchro hubs.
Push hu bs out of sleeves

138
Cleaning - checking.
Clean all parts In solvent Blow dean with compres·
sed air
Carefully check all parts Replace worn or damaged
pa rts Replace gaskets and seals

Group 43
M anual Transmission 77
M 46, assembly

Assembling transmission M 46
Special toois:
1801 Standard handle 5065 Drift . Installmg sealon shih selector rail
2412 Drift , installing mput shaft bearing 5177 Pullor, intermedlate shah beanngs. alumi-
2831 Press tool , installing mai n shah bearing num housing
2852 Adapter, Installing gear and synchro ring 5180 Drift. mtermediate shalt bearings. alummum
2867 Drift , installing bell housing seal housing
2986 Drift , mstalling intermediate shaft beanngs

Jl

Connect 1-2 and 3-4 synchro hubs.

POSition hub m sleeve so that hub slots align
chamfered teeth m sleeve. Insert dags (three) and
lock them with springs
NQTE With curved lock ring, align sprmgs to let free
ends press agamst synchro ring

.
,,. ,,
J2

Install bell housing seal.

2867 Use drift 2867 and standard handle 1801 .

-
J3

• Position rubber ring in joint.

,.~

Group 4 3
78 Manual Transmission
 M 46, assembly

J4

Install bushings on gearshift rod.

Use grease to relam rubber nng on right sIde

•
J5

Install seal for seleetor rail.

Drift 5065.

J6

Install:
- 3rd gear and syncro nng
- 3- 4 synchro hubs on mam shaft
- Lock nng
Use adapter 2852 when pressmg on gesr and hub

J7

Install:
- 2nd gear and synchro hub
- 1-2 synchro hub on mam shaft
- lock ring
Use adapter 2852 when pressmg on gear and hub

Group 43
Manual Transm ission 79
M 4 6, assembly

JB

•
Install 1 st gear and synchro ring on main
shaft.

J9

Install two intermediate shaft bearings.

Use dnft 2986 to press on bearlngs
NQTE Intermedlate shaft small end bearing IS
different for diesel appllcations
Use correct type bearings

10

Install bearing on input shaft.

Use drift 24 1 2 to press on bearing

J 11

Installlock ring on input shaft.

NQTE DO NOT install spacer ring on bearing at this
lime
It will be Instal led later on

"

Group 4 3
80 Manual Transmission
 M 4 6, assembly

- - - - - Special instructions for transmissions with aluminum housing - - - - -

Prior to further assembly, Intermedlate shaft pre-

tension should be determmed Follow operations
J12-J21

J 12

Position intermediate shaft in housing.

J 13

Position outer races for intermediate shaft

bearings.
Use drift 5180 , large outer diameter toward race

J 14

Install bell housing with gasket.

Torque bolts to
35-50 Nm - 25-35 It Ibs

J 15
Turn transmission to vertieal position .

J16
Eliminate clearance in intermediate shaft
bearings.
Use dnft 5180, small diameter toward rear race ,
Hold drift rigidly and knock race with light taps
Repeat while rotatmg shalt. until all clearance is gone
and shaft runs somewhat slugglsh

Group 43
Manual Transmission 81
M 46, assembly

J1 7

Measure distance between intermediate

shaft bearing outer race and rear surface of
housing.
Use depth gauge and note readmg

- J1B

Determine thickness of shims for

intermediate shaft.
Shah pre· tension should be O 03-0 08 mm Gasket
thlckness O 25 mm (memc only)

E)(ample.
Dlstance, race-surface 1 51
Gasket +025

1 76 1 76
Pre-tenSion +003 to +008

Shlm thlckness 1 7g to 1 84
Choose 1 .80 mm shlm thlckness
Shlms avallable O 05 mm
O 10mm
O 15 mm
lO'" O 35mm
050mm
O 70mm
100 mm

J19

Remove bell housing and gasket.

Group 43
82 Manual TransmIssIon
 M 4 6, assembly

J20
Remove outer races for intermediate shatt
bearings.
Careful ly knock mtermediate shaft until puller 5177
can grip races

J2 1

Lift out intermediata shaft.

5177
- - - End of special instructions for transmissions with aluminurn housing---

Proceed wi t h assembly, using same opera tIOns as for

transmission with east iron housing
Exception
- Outer races for interrnediate shaft bearings are
mstalled as described above
- Sh im thlckness is determined

J22

"
Install revorse gear shifter.
Installlock ring

J23

Install reverse gea, and shaft.

Group 4 3
M anual Transmission 83
M 46, assembly

J 24

Check and adjust reverse gear shaft

position.
Shaft end should be minImum O 05 mm - 0002 "
under houslng face

J25
Important!

Adjust elearance between reverse gear and

shift tork.
Correcl dearance IS O 1- 1 O mm _ O 004-0 04"
AdJust by knocklng shlft fork pivot pin aXIally with a
punch

J26

.. Position intermediate shaft in housing .

POSition on bottom of houslng

-. •
J27

Position main shaft in housing.

Group 43
84 Manual Trsnsn''IIsslon
 M 46, assembly

J28

Position thrust washer and bearing on main

shaft.
Beanng should be fllted with posl!lomng ring

J29

Press main shaft bearing into position.

Use press tool 2831
Press reverse gear toward transmiSSion center Check
that no gears comclde and become damaged

J30

Usa spacar for tool if bearing doas not align

correctly.
Spacer should be posItIOned between tool spindle
and housmg front end Bearing positioning ring
should be flush with housmg face when bearing is
correctly poSltloned

Installlock ring for main shaft bearing.

Group 4 3
Manual Transmission 85
- - - - - - - - ---

M 46, assembly

, J32

Install key in main shaft keyway.

J33

Install overdrive oil pump eccentric and

lock ring.

J34

Grease and install roller bearing in input

shaft.

J35

Position 4th gear synchro ring in synchro

hub.

, .~

Group 43
86 Manual Transmission
 M 46, assembly

J36

Attach input shaft to main shaft.

Push in shaft all the way

J37

lift up intermediate shaft.

POSition shaft so that bearings are correctly position-
ed in housing

Pull out input shaft so that spacer ring can

be positioned on bearing.
Then push in shaft again Spacer ring should lie
agalnst housing

east iron housing: J39

Install outer rBCes for intermediate shaft

bearings.

, .~

Aluminum housing:

Install intermediate shaft outer bearing

raeas.
Use drift 5180 , large outer diameter toward bearing
races

Measure distance between front end of

input shaft bearing and housing front
surface.
Use depth gauge Note reading (metric)

Group 4 3
Manual Transmission 87
M 4 6, assembly

J4 2

Measure distance between bell housing

surface and bearing seat bottom.
Use depth gauge Note reading (metric).

J43

Determine shim thickness for input shaft.

Axial clearance permitted: 0.01-0.20 mm.
NOTE Gasket thickness O 25 mm must also be con·
sidered Use metric measurements on ly

Example
Distance. tlywheel houslng
to bearmg bottom 560
Gasket thickness +0.25
5 75
Dlstance, beanng to
housing - 4 71

1 04 1,04
Clearance permined -001 to -0.15

Shim thlckness, mm 103 to O B9

Choose shim O 90 mm
Shims available O 60 mm
O 75mm
090mm
1.00 mm

J44
Install bell housing.
Use grease on gasket and shim to keep in place.
Torque 35-50 Nm ... 25-35 [Link]

Aluminum housing: J45

Install clutch fork.
Including spacer

J46
Install throw-out bearing.

Group 43
88 Manual Transmission
 M 4 6, assembly

Aluminum housing:

Turn transmission to vertical position.

M ake sure intermediate shaft bearings
have no clearance.
Use dnft 5180 with small diameter toward rear
bearmg race Hold tool rig!dly and knock on race
with light taps. Repeat while rotating shaft until all
clearance IS gone and shaft runs somewhat slugglsh.

J 48
east iron housing:

Turn transmission to vertical position.

Measure distance between intermediate shaft
bearing outer race and rear surface of housing .
Race should butt ro llers Use depth gauge Note
reading (metrie)

J49

Determine thickness of shims for

intermediate shaft.
Axial clearance permitted 0025-010 mm . Gasket
thiekness 0.25 mm. M etne only,

Example:
Distance, race to surfaee 1.4 3
Gasket +025

1.680 1,680
Clearance permitted -0025 0 100

Shlm thiekness 1 655 to 1 580

Choose 1 65 mm (alt 1 60 mm)
Shlms available 0.05 mm
O 10 mm
O 15 mm
O 35mm
O 50mm
O 7amm
100mm

Group 4 3
M an ual Transmission 89
M 46, assembfy

J50

- Measure distance between front of main

shaft bearing and housing rear surface.
Use depth gauge Note reading (metnc)

J51

Measure distance between rear cover

$urface and bearing seat bon om.
Use depth 9auge Note reading (metric)

J52

Oetermine shim thickness for main shaft.

A)(lal clerance permitted O 01-020 mm Gasket
thlckness O 25 mm

Example:
Dlslance, cover 10
beanng bonom 550
Gasket +025

575
Dlstance. bearing to
housmg - 471

1 04 1 04
Clearance permmed -001 to -O 20

Shlm thlckness 1.03to 084

Choose shlm O 90 mm
Shlms available O 60 mm
075mm
O 90mm
1 00 mm

Group 43
90 Manual TransmissIon
 M 46, assembly

J53

Install shift forks.

Make sure lugs position correctly

J5 4

Install shifter and gear selector rail.

Shlfter boss forward_

J55

Position gasket and shim pack for

intermediate shaft.

J56

Position main shaft shim pack in

intermediate housing.
Apply grease to shim to keep in place

J57

Install intermediate housing.

Insta ll two outer (Iower) bolts finger tight

Group 4 3
Manual TransmissIon 91
M 46. assembly

J58

Install gearshift rod.

Install sleeve on 10lnl

J59
Install gearshift carrier.
Note sequence bolt - washer - spacer- washer
Torque bolts to
35-50 Nm _ 25- 35 [Link]

J60

Install two inner (Iower) bolts for

intermediate housing.
Torque four lower bolls 10
35-50 Nm - 25- [Link]

Install overdrive.

J62

Install:
- lock pm for shiiter
- Gflde washers for selector plate assembly

Group 43
92 Manual Transmission
 M 46, assembly

J63

Install selector plate assembly and return

spring.

J6 4

Check operation ,
Install gearshlft lever wIthout lock screw and lock
ring
Hold selector plate assembly with palm Check gear·
shift operation, correct as necessary
Remove gearshlft lever

J65

Install :
- Detent ball and sprmg
- New top cover gasket

•
J66

Install top cover.

Torque bolts to
15--25 Nm _ 1 1-18 [Link]

Group 43
Manual Transmission 93
M 46, assembly

Install :
- Overdnve sWitch
- Back-up light switch
- Wires at overdrive solenoid
- Sound deadening material on gearshift carrier

J68

Fill oil.
Lower transmission rear and Fill 2.3 liters _ 2.4
US qts of Automatic Transmission Fluid. F or G

InstalIIevei plug .

Group 43
94 Manual Transmission
-
M 4 6, installation

Installing transmission M 46
Special tool. :
5972 Fixtur.

Kl

Position transmission and fixture 5972

assembly on lifting device.
FIxture In rear POSition to secure
transmiSSion ngldly on tlxture

K2

Install transmission.
Check that throw-out bearing IS correctly positioned
Intork
Raise transmission Tum transmission to be !ree from
propeller shalt when pushing il in from rear
Install two lower bolts at bell housing
Remove fixture and lifting device

Install:
- Starter motor and tlghten retaining bolts
- Front exhaust pipe braeket . Two bolts at bell
housmg, ene nu! at exhaust plpe
- Remaining bolts for bell housing
- Rubber nngs for front muftier

Group 43
Manual Transmission 95
M 4 6, installation
--
K4
As appropriate:

Attach clutch cabla.

Hook on return spring

K5
Install brackat for rubbar cU5hion.

K6

Install cross·mambar aS5ambly.

K7

Install:
- Propeller shaft to transmiSSion drive flange
- Speedometer cable

KB
Inside vehicle:

Install rubbar ring and plastic bushing.

Group 43
96 Manual Transm ission
 M 4 6, installation

K9

Check that sound deadening material is

correctly positioned.

Install gearshift lever.

Install retaining ring

From under vehicle: KIl

Attach gearshift rod to gearshift lever.

Push p ivot pm into poSition and Installlocking screw

K 12

Install reverse detent plate.

Group 4 3
Manual Transmission 97
M 46. Installation

K I3

Adjust clearance for reverse gear detent.

Engage 1st gear and adlust clearance between detent
plate and gear shltt lever
Correct clearance. 0 .5-1.5 mm - 0020-0060"
Then engage 2nd gear and recheck clearance

Install red and yellow wire in connector.

KIS

I nstall connectors for overdrive.

Then install panel on center console right sIde

Install connector for back-up light.

Then install panel on center console left slde_

Group 43
98 Manual Transmission
 M 46, installation

KIl

Install gearshift lever cover.

KIB

Connect battery ground cable.

,,

J>

•
IJDO I5

•
•

•
Group 43
Manual Transmission 99
•
•
•
•
, VOLVO SUPPORTS YOWNTARY
MECHANIC CERTIFICATlON
BY THE N.I.A.S.E.

(U,SA only)

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Your
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