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.