Removing and Installing Input and Output Shaft

Removing and installing input and output shaft
-Assembly-Transmission removed-

Remove Transmission case front section Removing and Installing Front Case Section






Remove lock plate
Apply special Tool 23 1 200
Hold output flange with Special Tool 23 0 020
Unscrew collar nut with Special Tool 23 1 210






Pull off output flange with Special Tool
33 1 150






Unscrew bolt (1).
Remove holder (2).
Unscrew bolt (3).






Remove shaft with reverse gear and needle bearing.






Pull out pin (4) for operating lever (5).
Pull out selector rail (6)
Remove operating lever (5).
Installation
Install operating lever that notch faces up and in direction of selector rail






Engage 4th gear.
Drive in pin (7), while counterholding

Note:
Only drive in pin (7) far enough that selector
shaft can be pulled back and out.







Radial oil seal (8) will also be pulled out.

Note: Rollers on selector shaft.

Installation:

Replace radial oil seal.
Remove selector arm.






Detach end plate.
Installation

Install end plate with sealing compound
Sealing surface must be thoroughly clean
and dried of oil.
Remove end plate(9).

Installation
Replace end plate.







Remove three springs.






Drive pin (10) out of the 3rd/4th gear shift fork.

Installation
Install a new pin.






knock out 3rd/4th gear shift rod forward.
Important
Lockpin (11) in shift rod.







Engage 2nd and reverse gears by moving 1st/2nd and 5th/reverse gear
shift rods forward.

Press input shaft, output shaft and layshaft out of the rear case section with special tool 23 1 050.






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






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

Installation:

check conditions of all bearings, replace if necessary.







Installation:

Install 3rd/4th gear shift fork and shift rods with shift-forks 1st/2nd and 5th/reverse gears.







Remove all locking and detent balls in rear case section.
Install the roller bearing with the large diameter end facing out.
Lubricate lockpins and locking arms with oil.






Install and cover after coating with sealing compound.
Install end covers with sealing compound.






Drive pin out of the selector arm








Hold 4 rollers in position with grease slide in selector shaft and install selector arm (1) at same time.

Important
Opening in selector shaft faces out.






Drive in 6 X 26mm pin (counter hold).






Lubricate sealing lips of radial oil seal with oil.
Drive in radial oil seal with Special Tool 23 1 240






Install selector rail
Groove (1) in selector rail faces up.
Install operating lever (5) with notch facing up and toward
selector rail.
Install pin (4)






Coat case rear section in area of reverse gear shaft with sealing compound
Surface must be thoroughly clean and dried of oil.






Install shaft with needle bearing and reverse gear.







Mount shaft with bolt (3)
Install bolt with a locking compound







Insert holder (2) press out and secure in this position







Install output flange.
Install collar nut with a locking compound
Apply Special Tool 23 1 200.
Hold output flange with Special Tool 23 0 020
Tighten collar nut with special tool 23 1 210






Install lockplate