Removing and Installing Complete Drive and Output Shafts

Complete Removal And Installation Of Input And Output Shafts


- Transmission removed.




- Unscrew drain plug.
- Drain off fluid.
- Secure special tool 23 0 100 on the bore of the drain plug.
- Fit transmission to assembly frame 00 1 490 with special tool 23 0 100.
- Remove clutch release mechanism and release lever.




When fitted:
- Lift out lockplate (1).




- Block output flange using special tool 23 0 020.
- Unfasten collar nut with special tool 23 1 210.




- Pull off output flange.

Note: If ease-of-movement is impaired, remove output flange with special tool 33 1 150.




- Remove radial seal with special tool 00 5 010.




- Remove cap (1).




- Remove compression springs (1) and cylinder pins (2).




- Remove locking stops and ball stops (3) (5 off) with help of a magnet (4).




Note: Note locking pin (1) in the central selector rod!




- Locking pin (1) on middle selector rod (2) must locate in centre of selector rod.

Note: To secure the position of the locking pin (1), the transmission must be shifted into 2nd gear.




- Shift into 2nd gear:
- Insert splint driver or screwdriver (1) in bore of selector shaft (2).
- Twist selector shaft (2) up to 1st left detent and press into the transmission.




- Unscrew bolts.




- Remove sealing ring.




- Unfasten screw (1) and reverse gear switch (2). Lever out cap (3).




- Remove spring (4) and arrester bolt (5).




- Unscrew screws (1 and 2).




- Drive dowel pin (1) out towards clutch case with a cotter pin extractor.




- Drive out cotter pin (2) with a cotter pin extractor.




- Unfasten screws on transmission case (9 off).




- Remove transmission from assembly frame 00 1 490 and put down with the output side facing upwards.
- Fit special tool 23 1 141 together with 23 1 142 and 23 1 143 and install on rear case section.
- Pull off rear case section.




- Remove middle selector rod until all 3 selector rods are at the same height.




- Remove retaining plate (1) and magnetic disc (2).




- Withdraw pin (3).
- Remove pivot lever (4).
- Remove gearshift rail (6).

Note: There are 4 rollers at the lower end of the selector shaft (5) and these can fall out when the selector shaft is removed.

- Pull out shift shaft (5).




- Position gears and shafts with front case section on special tool 23 2 400.




- Unfasten screws and remove guide tube.




Note: Two covered removal holes (1) are located on front end of radial sealing ring.




- Screw special tool 23 0 490 into one of the two removal holes.
- Pull radial sealing ring out of transmission housing with impact weight.




Caution! To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft during removal of the circlip (3).

- Lift out circlip (3) and pull off over special tool 23 2 460.




- Remove closing ring (4).




Caution! To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft during removal of the circlip (6).

- Lift off circlip (6) and secure to special tool 23 2 460.
- Pull special tool 23 2 460 with circlip (6) from the input shaft.
- Lift out shim (5).




- Secure special tool 23 1 141 to front case section with 2 screws.
- Pull front case section from gears and shafts.




- Take off needle bearing (1).
- Remove reverse gear (3) with reverse gear pins (2).




- Remove complete gear train with selector rods (1) from special tool 23 2 400.






Assembling transmission:
- Install complete gear train with selector rods in the special tool 23 2 400.




- Install reverse gear with collar (2) facing upwards and reverse gear shaft with long extension (1) in special tool 23 2 400.
- Coat locating face of short extension (3) on reverse gear with Loctite 574 seals compound.




- Check end float of the input shaft.
- Apply special tool 23 2 420 on the input shaft.
- Insert shim (2) and new circlip (1) in the groove.
- Check end float with a feeler gauge.
- End float 0.04 mm.

Note: Shims (2) can be obtained from Parts Service in thicknesses (X) of 2.3-2.65mm.




- Heat input shaft inner bearing race (1) in the front case section to approx.110-120 °C (hot air blower).
- The heating temperature must be precisely maintained. Check with a thermometer.
- Align selector rods with one another.
- After heating, insert the roller bearing (2) with thick grease into the bearing sleeve with large diameter facing upwards.




- Carefully attach the front case section.

Note: The 5th gear synchronizer ring can jam.

- After completely assembling the transmission, the 5th gear synchronizer ring can be loosened again by twisting the output/input shafts against each other.




- Install spacer (5).

Caution! To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft while installing the circlip (6).

- Slide new circlip (6) over the special tool 23 2 460 and install in the lower groove.




- Install closing ring (4).

Caution! To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft while installing the circlip (3). Slide new circlip (3) over the special tool 23 2 460 and install in the upper groove.




- Coat the radial seal sealing lip with ATF-oil. Push radial seal (1) over special tool 23 2 460 up to case.
- Remove special tool 23 2 460.




- Drive in radial seal (1) with special tool 23 2 430.
- Use plastic hammer to drive in.




- Install guide tube.
- Install screws with Loctite 243 screw locking varnish.
- Tightening Torque: M8x22 18 Nm
M8x30 25 Nm
M6 10 Nm




- Secure reverse gear shaft in front case section.
- Install screw (1) with Loctite 243 screw locking varnish and tighten.
- Tightening torque: M8 25 Nm
M10 45 Nm
- Loosen screw (2) from special tool 23 2 400.




- Remove front case section and gear train from special tool 23 2 400 and place to one side with output end uppermost.




- Attach 4 rollers to the selector shaft with Vaseline.




- Insert selector shaft (1) into front case section. Insert gearshift rail (2) with the opening upward into the case.




- Install pivot lever with wider head (1) facing the selector rod (2).
- Polished side must face towards case.
- Attach pivot lever with the pin (3).




- Install locking pin (1) in the selector rod (2) with Vaseline and secure in the centre.




- Clean case sealing surfaces and coat with Loctite 574 seals compound.
- Place retaining plate (1) with flat side uppermost on 2nd gear on countershaft. Screw special tool 23 2 440 into the retaining plate (1)
- Install magnetic disc (2) in the case. Align selector rods with one another. Coat locating face of reverse gear shaft (3) with Loctite 574 seals compound.




- Lift radial seal on selector shaft out of rear case.
- Heat inner bearing race (1) and rear case section in area around bearing to 110-120 CC (hot air blower).
- The heating temperature must be precisely maintained.
- Check with a thermometer.




- Insert rear case section up to limit stop. Install 3 screws with new sealing rings. Remove special tool 23 2 440.
- Screw in fourth screw with new sealing ring. Tighten down all screws.
- Tightening torque: 10 Nm




- Lightly secure front and rear case sections with opposite two screws.
- Place rear case section on support 23 0 100 and again lift with the assembly hoist 00 1 490.




- Drive in cotter pin (1).




- Drive in cotter pin (2).




- Screw in all case screws and tighten down.
- Tightening torque: 22 Nm




- Loosen bolt (1).
- Install screw (2) with Loctite 243 locking varnish.
- Tighten the screws (1 and 2).
- Tightening torque: M8 25 Nm
M10 45 Nm




- Install radial seal for selector shaft and output shaft.
- Coat sealing lip with ATF-oil.
- Push in output shaft radial seal with special tool 24 0 110 and selector shaft radial seal with special tool 23 1 240.

Note: Use a plastic hammer to drive in seal.




- Heat output flange to approx. 80°C (hot air blower) and fit to output shaft.
- Coat thread and locating face of collar nut (1) with Loctite 243 locking varnish.
- Block output flange using special tool 23 0 020.
- Tighten collar nut (1) with special tool 23 1 210.
- Tightening torque: Initially tighten to 190 Nm, then loosen and re-tighten to 120 Nm




- Install arrester and locking balls.
- Order: Locking ball (1), arrester ball (2) and locking pin (3).




- Install springs (1) and cylinder pins (2).




- Attach cap (1).
- Install screws with Loctite 243 screw locking varnish and secure.




- Install arrester bolt (1) and spring (2).

Note: Roller (3) must be positioned horizontally.




- Install shear-off screw (1) with Loctite 243 locking varnish and tighten down.
- Install the reverse gear switch.
- Tightening torque: 20 Nm
- Knock in plug (3)
- Installing clutch release mechanism and release lever.