Replacing Bearing of All Transmission Shafts

Replacing bearings of all transmission shafts
-transmission removed-






Remove input/output shaft assembly

A). input Shaft, layshaft in Case Front section

Input Shaft:
Drive out grooved ball bearing with Special Tools 23 1 480 and 00 5 500.






Note:
Collars is on clutch end.

Layshaft:
Loosen circlip (1) with a single knock from Special Tool 23 1 270 wised in conjunction with Special Tool 00 5 500







Lift out circlip (2).
Remove space (3).







Drive out bearing shell toward the inside with Special Tools 23 1 270 and 00 5 500.






Version with O-ring (4) with a feeler gage blade

Installation

Replace and insert new O-ring coated with engine oil in groove prior to
installation of the bearing shell.







B). Output shaft layshaft in case

output shaft:
unscrew bolt(1).

Caution:
Spring pressure

Remove spring (2).

Installation:

Install bolt with a bolt cement







Install Special tool 23 1 250 for removal of the
selector arm.






Remove socket head screw (3).

Installation:

Install screw with a bolt cement

Tightening torque






Remove selector arm from above.

Note:
Roller






Installation:

Install spring (2).
Insert selector arm with Special Tool 23 1 250.
Swing out selector arm with the roller
over locking lever(4).







Move end of spring (3) over the raised point
into installed position
Press down on the selector arm in this position (do not knock down).
Install the socket head screw with a bolt cement and tighten with correct
torque before removing the special tool.







Unscrew bolt.
Take off locking lever (4) and spacer (5)

Remove bearing holder (6)

Installation:

Install bolt with a large washer.







Installation:

Check the installed position of locking lever (4) and trust pin (7).






Lift out radial oil seal
Drive out grooved ball bearing with Special tools 23 1 120 and 00 5 500.

Note:
Shim X.






Determine thickness of shim X.
Measure distance (A).







Measure distance (B).

Example:

A = 17.5 mm (0.689")
B = 17.0 mm (0.669")
----------------------
X = 0.5 mm (0.020") thick shim








Heat rear case section in area of the grooved ball bearing to about 80 ° C (175 ° F).
Install shim X.
Install grooved ball bearing.
Close cage faces in.
If necessary, drive in against the stop
with Special Tool 24 1 060.






Layshaft:
Apply the stronger end of Special Tool
23 1 280 in the bearing shell.
If applicable, remove the turning lock
on the side of the drain plug.








Apply Special Tool 33 4 020
Screw on Special Tool 23 1 300
Pull out bearing shell.







Installation:

Install bearing shell that the slot in the bearing shell
is aligned with the bead
(turning lock) in the case.






Drive the bearing shell with Special tools 23 1 260 and 00 5 500.






Determining Axial Play of layshaft
Install circlip (2).






Install old shims
Drive in bearing shell to fit tight in the front case section
with Special Tools 23 1 260 and 00 5 500.

Important:
The oil groove must be aligned with the groove in the case.






Place layshaft with roller bearings in the rear case section.







Mount front case section and secure with two bolts opposite each other.
Center front case section slightly with dowel pins.
Unscrew oil filler plug (1).







Mount holder with dial gage.
Dial gage must bear on tooth of the layshaft.







Check axial play of the layshaft through the bore for the oil filler plug.
Axial play: 0.13 to 0.23 mm (0.005 to 0.009").

Correct when necessary by removing the bearing shell and replacing the shim
with a thicker one.






Install gear wheel set.
Determine thickness of shim for the input shaft.
Install old shim and circlip.
Reduce play to 0... 0.09 mm (0 to 0.0035").
Determine thickness of shim for the guide sleeve