Part 1 of 2

Complete Drive (Input) and Output Shaft, Disassembly and Assembly
Remove transmission.

Remove clutch release unit/lever.

Unscrew drain plug.

Drain off oil.





Screw special tool 23 0 100 (transmission bracket) into hole for drain plug and secure.

Mount special tool 23 0 100 on assembly stand 00 1 490.

Recycling:
Catch and dispose of escaping transmission fluid.
Observe country-specific waste-disposal regulations.





Release screws and pull out guide tube.





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.

Withdraw radial seal from transmission housing with 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).





Remove housing screws.





Pull off front housing section with 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. Catch pin for 5th/reverse gear falls out.

Always replace bearings and segments during removal.





Remove pressure spring (1) and thrust pin (2).

Remove roller bearing (3).





Withdraw shift shaft (4).

Caution: Needles on shift shaft.

Remove 5th/reverse gear shift arm towards top.





Remove 2 bearing pins on right.

Note: Bearing pins must be replaced.





Remove 3 bearing pins on left.

Note: Bearing pins must be replaced.





Remove locking lever (1) completely.

Remove pressure spring (2) and thrust pin (3).





Remove screw (4).

Remove reverse gearwheel with needle bearings, thrust washer, pin and half shell.





Pierce sealing cover (5) on side.

Lever out sealing cover (5) in hole with a screwdriver.

Installation:
Replace sealing cover.





Engage a gear by hand.

Grip output flange with special tool 23 0 020.

Release screw (6).

Caution: Left-hand threads.

Remove washer (7). Disengage selected gear again.





Grip output flange with special tool 23 0 020.

Release collar nut (1) with special tool 23 2 320.





Detach output flange with special tool 33 1 150.





Compress gear train at 5th/reverse gear sliding sleeve with countershaft with special tool 23 2 250.





Attach special tool 23 2 370 to 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.

When pressing out, make sure gear train and countershaft do not get jammed.

Installation:
The bearings or elements of the bearing brackets could be damaged while pressing out the drive and output shafts.
Always replace bearing and segments during removal.





Remove gear train with 1st/2nd and 3rd/4th gear shift arms and countershaft.





Installation:
Clean housing.

Drive out sealing cap (11 and 2) on rear housing section with a mandrel from inside to outside.





Installation:
Replace sealing cap.

Replace bearing (1) and (2) (output shaft, countershaft and retaining plates).





Lever out radial seal (3 and 4) for output and selector shafts.





Compress gear train at 5th/reverse gear sliding sleeve with countershaft. Use special tool 23 2 250.

Attach 3rd/4th gear shift arm with sliding blocks to 3rd/4th gear slide sleeve.

Rest shift arm on 3rd gear wheel of output shaft.

Connect shift arm with catch (1) in direction of drive shaft on left.





Insert gear train with shift arm in rear housing section.





Attach 1st/2nd gear shift arm with sliding blocks to 1st/2nd gear slide sleeve.

Caution: Connect shift arm with catch (1) in direction of drive shaft on left.

Attach special tool 23 2 330 to output shaft journal. Draw in output shaft with special tool 23 2 330 until firmly seated.

When drawing in, make sure shift arms and countershaft do not get jammed, align if necessary.

Remove special tool 23 2 330.





Center 3rd/4th gear shift arm by hand with bore in housing.

In this position, screw in bearing pins (2) in succession on left and right and then tighten down.






Oil sealing lip of radial seal.

Drive in radial seal (3) for output flange with special tool 232300.

Caution: Use a plastic hammer to knock in.





Heat output flange to approximately 80°C (hot-air blower).

Push output flange onto output shaft.

If necessary, drive on to fit tight with special tool 23 1 160.