Removing and Installing Front Case Section

Disassembly Procedure:
- Remove transmission.





- Mount Special Tool 23 0 090 on Special Tool 00 1 490.
- Mount transmission on special tool assembly.
- Drain oil.
- Remove guide sleeve.





- Unscrew backup light switch.
- Remove cap (1).
- Pull Out spring (2) and lockpin (3).
- Check installed position!





- Remove snap ring (4).
- Remove washer (5).

Installation Note: Always replace snap ring.





- Unscrew bolt (6).

Installation Note: Install bolt with a bolt cement**.





- Drive out cylindrical pins.
- Unscrew bolts.

Installation Note: Check length of bolts. Bolt (1) = 8 x 60 mm.





- Pull off front case Section with Special Tools 23 1 460 and 33 1 301.

Assembly Procedure:





- Install roller bearing on layshaft that small diameter end faces up.

NOTE: Coat rollers with grease and press in, in order to avoid clamping of rollers while mounting the front case section.





- Coat case front section with a surface sealing compound in area of the reverse gear shaft. Surface must be cleaned thoroughly and dried of oil.
- Unscrew oil drain plug.
- Install case front section.





- Align layshaft through bore for oil drain plug that roller bearing of layshaft slides into bearing shell.
- Mount case front section.
- Install lockpin and reverse gear switch.

NOTE: Input shaft axial play must be adjusted after replacing case or bearing.

Input Shaft Axial Play Adjustment:
- Adjust play to 0.0 - 0.09 mm (0.00 to 0.0035 in).
- Determine thickness of spacer.





- Measure distance (A).





- Measure distance (B).

EXAMPLE:
A 3.0 mm (0.118 in)
- B 2.6 mm (0.102 in)
-------------------------------
0.4 mm (0.016 in) spacer thickness

- Install correct shim.

Installation of Guide Sleeve:





- Install washer (5).
- Install snap ring (4).





- Mount guide sleeve in such a manner that oil groove (1) is aligned with oil bore (2) in the transmission case, or that arrow on face points to middle of layshaft.
- Install guide sleeve and bolts with a surface sealing compound.
- Sealing surface and bolts must be cleaned thoroughly and dried of oil.