Removing and Installing Input and Output Shaft Assembly

Removing and Installing Input and Output Shaft Assembly

-Transmission Removed-






Remove Front case section
Lift out lockplate.
Apply Special Tool 23 1 200.
Hold output flange with Special Tool 23 0 020.






Pull off output flange with Special Tool 33 1 50






Remove end plugs (1...3)

Caution: Spring force

Installation

Replace end plugs






Remove three springs







Pull out three catch pins with a circlip
pliers as far as possible.
Catch pins can only be pulled out
completely after removal of the lock.






Drive pins (4 and 5) out of the 3rd/4th
gear shift fork while counterholding.
New Version: 1 pin






Push back leaf spring (6) for reverse
gear with Special Tool 23 2 170 far
enough, until shift finger (7) is accessible.
It must be possible to turn the shift
shaft back and forth easily.






Swing shift finger (8) out of groove in the shift rod.






Pull out 3rd/4th gear shift rod







If applicable, remove lock in hexagon
socket of bolt.
Unscrew bolt (9).

Note: Seal between case and bolt.






Remove reverse gear shaft, reverse gear wheel with needle bearing
and thrust washer.






Remove bolt (10) for operating lever.







Note: Engage reverse gear by sliding the operating sleeve forward before pressing out the gear wheel set.







Press input shaft, output shaft and layshaft out of rear case section with
Special Tool 23 1 050.

Note: Use a piece of wood, aluminum or something similar between claws and sealing surface to avoid damaging the sealing surface.

Note: Make sure that shift rods and layshaft do not clamp while pressing out. layshaft must not fall down in this step.

Installation

Check condition for all bearings, replacing if necessary.







Installing

Reverse gear is engaged.
Install input and output shafts with shift rod for 1st/2nd gears, 3rd/4th
gear shift for, shift rod for 5th/reverse gears, shift shaft and layshaft in rear
case section.

Note: Check Installed position of operating lever (1).






Pull input shaft, output shaft and layshaft into rear case section
with Special Tools 23 1 300 and 23 2 150.

Note: Make sure that shift rods, shift shaft and layshaft do not clamp while pulling in.






Take out reverse gear
Slide in 3rd/4th gear shift rod with openings (2) facing up.
New version: one opening.







Drive in pins for 3rd/4th gear shift fork while counterholding.
New version: 1 pin.






Remove Special Tool 23 2 170 for the leaf spring.

Note: Roller (3) on leaf spring (6) must engage in the shift finger (7).






Install bolt (9) for operating lever.
Tip of bolt must engage in bore in operating lever.
Tighten torque.






Insert three catch pins with springs in case.
Install new end plugs approx. 0.5 mm (0.020") below the case edge
and punch lock slightly.






Install thrust washer (1) with angle (2) in upper opening
on the case.
New Version: without angle.






Install reverse gear wheel with long collar facing case, two
needle bearings and shaft.






Install seal (11) on bolt.
Tighten bolt (9) to correct torque and install new locking cap.







Drive in radial oil seal flush with Special Tool 23 2 160.
Lubricate sealing lip with oil.






Insert or knock on output flange.
Install collar nut with a bolt cement
Apply Special Tool 23 1 200.
Hold output flange with Special Tool 23 0 020.
Tighten collar nut with Special Tool 23 1 210.
Tighten torque.






Install and lock lockplate in the groove.