Disassembly and Assembly

Remove and install the input and output shafts (S5D 260Z/310Z/320Z)

Remove the transmission (depending on model).
Remove the clutch operator/lever, refer to Clutch M/T.





Unscrew drain plug.
Drain oil.
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 out radial seal from transmission housing with the aid of impact weight.





Remove left bearing pin and screw for reverse gear pin in front housing section.





Remove reverse gear switch and right bearing pin in front housing section.





Lever out retaining ring (1).
Remove sealing cover (2).





Remove pressure spring (3) and catch pin (4).





Unscrew case bolts.





Pull off front case section using Special Tools 23 2 280 and 331 301.

Caution:
Bearings or elements of the bearing brackets could be damaged while pulling off the front case section.
Always replace bearings or elements after removal.





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





Pull out selector shaft (4).

Caution: Needles on selector shaft.

Take off 5th/reverse gear shift arm upwards.





Remove 2 right bearing pins.





Remove 3 left bearing pins.

Note: Bearing pins must be replaced.





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





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





Pierce sealing cover (5) on side.
Lever out sealing cover (5) with a screwdriver inserted into the hole.

Installation:
Replace sealing cover.





Engage a gear by hand.
Grip 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 1 150.





Compress gear set at 5th/reverse gear operating sleeve with countershaft with Special Tool 23 2 250.





Attach Special Tool 23 2 370 on output shaft and countershaft.
Attach Special Tool 23 1 050 to housing sealing surface and center of Special Tool 23 2 370.

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

Press out gear train and countershaft uniformly.
Make sure that the gear train and countershaft do not jam while pressing out.

Installation:
The bearings or elements of the bearing brackets could be damaged while pressing out the drive and output shafts.
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 (11 and 2) on rear section of housing outwards from inside using a drift.

Installation:
Replace sealing caps.





Replace the bearings of the output shaft, layshaft and retaining plates (1 - 2).





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 jammed 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, refer to Manual Transmission/Transaxle, Specifications.





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 suitable bolt cement so 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, refer to Manual Transmission/Transaxle, Specifications.





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 suitable bolt cement.

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, refer to Manual Transmission/Transaxle, Specifications.
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 suitable sealing compound and install.
Install pin (3), thrust washer (4), needle bearing (5) and reverse gear (6) with collar (7) facing the case.
Coat shoulder of the bolt head with suitable sealing compound.
Install bolt (8) with suitable 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 5thlreverse gear shift arm.





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





Center locking lever (1) with the bores by hand.
Fit and secure the bearing pins (2) and (3) on the left and right.
Tightening torque. refer to Manual Transmission/Transaxle, Specifications.
Check movement of the locking lever.





Guide in selector 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 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 drive shaft and replace the retaining elements (1).
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 suitable 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 drive shaft.
Place supporting shells (1) on the drive 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.
Center 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, refer to Manual Transmission/Transaxle, Specifications.
Remove Special Tool 23 2 270 from shift shaft.





Center 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, refer to Manual Transmission/Transaxle, Specifications.

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





Install bearing pin (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, refer to Manual Transmission/Transaxle, Specifications.





Coat shoulder of the bolt head with a suitable sealing compound.
Insert the screw (1) for the reverse gear bolt with suitable screw retaining agent.
Tighten both screws.
Tightening torque, refer to Manual Transmission/Transaxle, Specifications.





Place catch pins (1 - 3) with compression 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 to 2.6 mm.





Lubricate sealing lip of radial sealing ring with ATF.
Apply Special Tool 23 2 380 on the input shaft.
Push on 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, refer to Manual Transmission/Transaxle, Specifications.