Removing and Installing Front Case Section

Removing and Installing/Sealing Transmission Front Case Section

- 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.
- Lift out circlip (1).





- Unscrew backup light switch.
- Drive back cylindrical pins.
- Unscrew bolts.





- Pull loose case front section with Special Tool 23 1 460 and 33 1 301.





- Pull off case front section.

Installation Note: Replace gasket,





NOTE: Clean magnet (2) in case rear section.





- Drive out end cap (3).

Installation Note: Replace end cap and insert with Loctite No. 573,





- Drive out grooved ball bearing in direction of clutch housing.

Assembly Procedure:





- Hold thrust washer (4) with angle facing bore (5) in case rear section on reverse gear shaft with grease.
- Install gasket with grease.





- Apply Special Tool 23 2 180 on selector shaft.





- Install case front section and bolt to case rear section.
- Remove Special Tool 23 2 180.
- Install end cap for selector shaft.

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

Input Shaft Axial Play Adjustment:
- Input shaft must rest on synchromesh ring.





- Measure distance (A) from guide sleeve sealing surface to input shaft.





- Measure distance (B) from guide sleeve sealing surface to circlip bearing surface.

NOTE: If a spacer is found between the circlip and case when removing the bearing, it must be installed again for measuring distance.





- Measure distance (C) from bearing outer race to circlip.

NOTE: Circlip must fit tight in groove for measuring.

EXAMPLE:
A 25.3 mm (0.996 in)
- B 10.1 mm (0.398 in)
---------------------------------
15.2 mm (0.598 in)
- C 14.0 mm (0.551 in)
---------------------------------
1.2 mm (0.047 in)

Axial play required: 1.1 to 1.3 mm (0.043 to 0.051 in).
Circlips are available from Parts in different thicknesses for corrections.

- Heat grooved ball bearing inner race and case front section in area of bearing to approx. 80°C (175°F).





- Push grooved ball bearing on to input shaft as far as possible.





- Press grooved ball bearing on to input shaft and into case front section with Special Tools 23 1 007, 23 1 000 and 23 1 006.

NOTE: Insert Special Tools 23 1 006 that flat side faces input shaft.





- Drive on grooved ball bearing further simultaneously with light hammer.

NOTE: Coat operating pin of the reverse gear switch with oil.