Removing and Installing Complete Drive and Output Shafts

Removing And Installing Complete Drive And Output Shafts


- Remove the transmission Service and Repair
- Remove the clutch operator / lever.




- Unscrew drain plug.
- Drain off fluid.
- Screw special tool 23 0 100 (transmission support) into bore of drain plug and secure.
- Locate special tool 23 0 100 (support) in special tool 00 1 490 (assembly frame).




- Loosen the screws and pull off the guide pipe.




Note: Two covered removal holes (1) are located on end face of radial seal.




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




- Unscrew left bearing shaft bolt and reverse gear shaft bolt in the front case section.




- Unscrew reverse gear switch and right bearing shaft bolt in the front case section.




- Lift out circlip (1).
- Remove sealing cap (2).




- Lift out spring (3) and catch pin (4).




- Unscrew case bolts.




- Pull off front case section using special tools 23 2 280 and 33 1 301.

Caution! Bearings or elements of the bearing brackets could be damaged while pulling off the front case section.

- Catch pin for 5th/R gear falls out.
- Always replace bearings or elements after removal.




- Remove loose spring (1) and thrust pin (2). Take off needle bearing (3).




- Pull out shift shaft (4).

Caution! Needles on shift shaft.

- Take off 5th/reverse gear shift arm upwards.




- Remove 2 right bearing pins.

Note: Bearing pins must be replaced.




- Remove 3 left bearing pins.

Note: Bearing pins must be replaced.




- Remove complete locking lever (1). Remove spring (2) and thrust pin (3).




- Remove screw (4).
- Remove reverse gear with needle bearings, thrust washer and half-shell.




- Pierce sealing cap (5) at side.
- Lever out sealing cap (5) with a screwdriver inserted into the hole.

Installation:
- Replace sealing cap.




- Engage a gear by hand.
- Block output flange using special tool 23 0 020.
- Unscrew bolt (6).

Caution! Left-hand threads.

- Take off washer (7).
- Take out engaged gear.




- Block output flange using special tool 23 0 020.
- Unscrew collar nut (1) with special tool 23 2 320.




- Pull out output flange using special tool 33 1150.




- Compress gear set at 5th/reverse gear operating sleeve with layshaft.
- Use special tool 23 2 250.




- Apply special tool 23 2 370 on output shaft and layshaft.
- Apply special tool 23 1 050 on case sealing surface and middle of special tool 23 2 370.

Caution! Use a piece of wood, plastic or similar on the sealing surfaces

- Press out gear set and layshaft uniformly.
- Make sure that the gear set and layshaft do not clamp while pressing out.

Installation:
- The bearings or elements of the bearing brackets could be damaged while pressing out the input shaft and output shaft.
- Always replace bearings or elements after removal.




- Remove the gear set with shift arms for 1st/2nd and 3rd/4th gear and layshaft.




Installation:
- Clean the case.
- Drive sealing covers (1 and 2) on rear section of housing outwards from inside using a drift.
- Replace sealing caps.




- Replace the bearings of the output shaft, layshaft and retaining, plates (1-2), refer to "Replace the Bearings of All Transmission Shafts"




- Lever out radial sealing rings (3 and 4) for the output shaft and shift shaft.




- Compress gear set at 5th/reverse gear operating sleeve with layshaft. Use special tool 23 2 250.
- Place the shift arm for 3rd/4th gear with sliding blocks on the operating sleeve at 3rd/4th gear.
- Position the shift arm on the 3rd gear wheel of the output shaft.
- Install shift arm with lock (1) in direction of the left-hand side input shaft.




- Place gear set with shift arm in the rear case section. Place the shift arm for 1st/2nd gear and sliding blocks in the operating sleeve 1st/2nd gear.

Caution! Install shift arm with lock (1) in direction of the left-hand side input shaft.




- Apply special tool 23 2 330 on the output shaft journal. Pull output shaft in to fit tight with special tool 23 2 330.
- Make sure that shift arms and layshaft are not canted while pulling in; align if necessary.
- Remove special tool 23 2 330.




- By hand, align the shift arm for 3rd/4th gear with the bore on the case. In this position, turn the bearing pins (2) one after another on the left and right, then secure.
- Tightening Torque: 45 Nm




- Lubricate sealing lip of radial sealing ring with oil. Drive in radial sealing ring (3) for the output flange with special tool 23 2 300.

Caution! Use a plastic hammer to knock in.




- Heat output flange to about 80°C with a hot air blower.
- Slide output flange on to the output shaft.
- If necessary, drive on to fit tight with special tool 23 1 160.




- Install collar nut (1) with bolt cement that its flat side faces the output flange.
- Block output flange using special tool 23 0 020.
- Secure collar nut with drive socket 23 2 320.
- Tightening Torque: Initially tighten to 190 Nm, then loosen and tighten to 120 Nm




- Heat ball bearing inner race (2) for layshaft to about 80°C with a hot air blower.
- Press on ball bearing inner race (2) to fit tight with special tool 23 1 160; drive on with light knocks if necessary.




- Install washer (3) and bolt (4) with bolt cement, refer to BMW Parts Service.

Caution! Bolt (4) has left-hand threads.




- Remove special tool 23 2 250 from the gear set.
- Engage a gear.
- Block output flange using special tool 23 0 020.
- Tighten the screw (4).
- Tightening Torque: 30 Nm
- Disengage the gear.




- Insert and drive in sealing cap (1) flush with special tool 23 2 150.




- Coat half-shell (2) in area of the bolt bore with sealing compound and install.
- Install shaft (3), thrust washer (4), needle bearing (5) and reverse gear (6) with shoulder (7) facing the case.
- Coat shoulder of the bolt head with sealing compound.
- Install bolt (8) with bolt cement , but do not tighten.




- Install 5th/reverse gear shift arm and slide with catch (1) facing to the left in the 5th/reverse gear operating sleeve.




- Guide in locking lever (1) with long tongue (2) in the slot of the 5th/reverse gear shift arm.




- Swing the locking lever (1) inwards and, at the same time couple it into the recesses of the shift arms 1st/2nd and 3rd/4th gear.




- Centre locking lever (1) with the bores by hand.
- Fit and secure the bearing pins (2) and (3) on the left and right.
- Tightening Torque: 45 Nm
- Check movement of the locking lever.




- Guide in shift shaft (4) horizontally.
- Attach 4 rollers with grease.




- Drive in radial sealing ring (1) for the shift shaft with special tool 23 2 260.




- Hold the shift shaft in neutral position with special tool 23 2 270.
- Use a 8 mm bolt and cylindrical pin (2) from the shift joint or a suitable mandrel for holding the shift shaft.




- Clean the front case section.
- Drive out sealing cap (3) for the catch pin from inside to outside using a punch.

Installation:
- Replace sealing caps.




- Replace the bearings of the input shaft and replace the retaining elements (1), refer to "Replace the Bearings of All Transmission Shafts"
- Remove the retaining plates (1).




- Place magnet (4) in the rear case section.
- Install needle bearing (5) with the small diameter end on the outside.

Note: Coat needles with grease and press them in to avoid canting of the needles when mounting the front case section.

- Clean and coat case sealing surfaces with a sealing compound.




- Hold the 5th/reverse gear shift arm in horizontal position with a piece of string to make installation easier.




- Mount the front case section as far as centering pins (1).
- To center the case, screw 2 M8 x 75 mm auxiliary screws opposite one another on the left and right into the rear section of the case.




- Place special tool 23 2 293 (thrust ring) from special tool 23 2 290 in the front case section.




- Apply special tool 23 2 290 on the input shaft.
- Place supporting shells (1) on the input shaft that the tapered sides face in.
- Unscrewing the spindle presses the front case section on to the input shaft.




- Press the front case section on only so far that the piece of string can still be removed after installation of the right bearing shaft.
- Centre 5th/reverse gear shift arm (1) with the bore and screw in the right bearing shaft (2) by hand, but do not tighten.

Note: Replace bearing pin (2). Clean thread in housing. Remove piece of string.

- Press front section of housing firmly home.




- Remove complete special tool 23 2 290.
- Remove centering bolts from case.
- Secure the front section of the case to the rear section.
- Tightening Torque: 22 Nm
- Remove special tool 23 2 270 from shift shaft.




- Centre 5th/reverse gear shift arm (1) with the bore and screw in the left bearing shaft (2) by hand.
- Secure the bearing pins (2) on the left and right.
- Tightening Torque: 45 Nm

Note: Replace bearing pin (2). Clean thread in housing.




- Install bearing shaft (3) for the locking lever.
- This requires turning the transmission until bore (4) in the locking lever is aligned with the bore in the case.
- In this position, turn the bearing pins (3) by hand and secure.
- Tightening Torque: 45 Nm




- Coat shoulder of the bolt head with a sealing compound.
- Insert the screw (1) for the reverse gear bolt with screw retaining agent.
- Tighten both screws.
- Tightening Torque: 20 Nm




- Place catch pins (1-3) with springs in the shift arms.




- Knock in sealing caps (5-7) with special tool 23 2 360.




- Catch pin (8) and spring (9)

Caution! Check installed position of catch pin (8).

- Roller must be horizontal.




- Install sealing cap (1) in bore (2) with special tool 23 2 350 and push in as far as possible.




- Install circlip (3) and press in as far as groove with special tool 23 2 350.
- Check for correct seating of the circlip (visual inspection).
- Install the reverse gear switch.




- Install spacer (4).

Caution! Special tool 23 2 380 must be used on the input shaft while installing circlip (3) to avoid damaging the input shaft.

- Slide circlip (3) over special tool 23 2 380 and install it in the groove.
- The circlip must seat in the groove without play. Replace circlip with a circlip of correct thickness. Circlips are available in different thicknesses in steps from 2.2-2.6 mm.




- Lubricate sealing lip of radial sealing ring with ATF.
- Apply special tool 23 2 380 on the input shaft.
- Drive in radial sealing ring (1) as far as case.




- Remove special tool 23 2 380.
- Drive radial sealing ring (1) in flush using special tool 23 2 340

Caution! Use a plastic hammer to knock in.




- Install guide tube.
- Tightening Torque: M8x22 18 Nm
M8x30 25 Nm
M6 10 Nm