Part 2 of 2

Fit collar nut (1) with flat side pointing to output flange with screw retaining compound.

Grip output flange with special tool 23 0 020.

Secure collar nut with drive socket 23 2 320.






Heat ball bearing inner race (2) for countershaft to approximately 80°C (hot-air blower).

Press on ball bearing inner race (2) with special tool 23 1 160 until firmly seated, drive on with gentle taps if necessary.





Install washer (3) and screw (4) with screw retaining compound.

Caution: Screw (4) has left-hand thread.





Remove special tool 23 2 250 from gear train.

Engage a gear.

Grip output flange with special tool 23 0 020.

Tighten down screw (4).


Disengage selected gear again.





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





Coat half shell (2) with sealing compound in area of screw bore and install.

Install pin (3), thrust washer (4), needle bearing (5) and reverse gear wheel (6) with collar (7) pointing to housing.

Coat collar of screw head with sealing compound.

Install screw (8) with screw retaining compound but do not tighten down.





Install 5th/reverse gear shift arm with sliding blocks with catch (1) to left in 5th/reverse gear sliding sleeve.





Insert locking lever (1) with long tongue (2) into slot of 5th/reverse gear shift arm.





Swivel locking lever (1) inwards and in so doing engage in recesses of 1st/2nd and 3rd/4th gear shift arms.





Center locking lever (1) by hand with bores.

Install bearing pins (2) and (3) on left and right and tighten down.


Carry out movement check on locking lever.





Insert selector shaft (4) in horizontal position. Apply grease to 4 rollers.





Drive in radial seal (1) for selector shaft with special tool 232260.





Secure selector shaft with special tool 23 2 270 in neutral position.

Use a 8 mm bolt and cylindrical pin (2) from the shift joint or a suitable mandrel for holding the shift shaft.





Clean front housing section. Drive out sealing cap (3) for locking pin with a mandrel from inside to outside.

Installation:
Replace sealing cap.





Replace bearing of drive shaft and retaining segments (1).

Remove retaining plates (1).





Insert magnets (4) in rear housing section.

Attach roller bearing (5) with small diameter facing outwards.

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

Clean housing sealing surfaces and coat with sealing compound.





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





Attach front housing section up to centering pin (1).

Insert 2 auxiliary screws M8 x 75 mm for centering housing opposing on left and right in rear housing section.





Install special tool 23 2 293 in front housing section.

Attach special tool 23 2 290 to drive shaft.





Attach support shells (1) to drive shaft with conical side facing inwards.

Unscrewing the spindle presses the front case section on to the input shaft.





Press on front housing section only to such an extent that auxiliary cord can be removed again after installation of right bearing pin.

Center 5th/reverse gear shift arm (1) with bore and install right bearing pin (2). Do not tighten down.

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

Remove auxiliary cord.

Press on front housing section as far as it will go.





Remove special tool 23 2 290 completely.

Remove auxiliary screws from housing.

Clean front housing section to rear section.


Remove special tool 23 2 270 from selector shaft.





Center 5th/reverse gear shift arm (1) with bore and screw in left bearing pin (2) by hand.

Screw in left bearing pin (2) by hand.

Tighten down bearing pins (2) on left and right.


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





Install bearing pin (3) for 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.






Coat collar of screw head with sealing compound.

Install screw (1) for reverse gear pin with screw retaining compound.

Tighten both screws.






Install catch pins (1 ... 3) with pressure springs in shift arms.





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





Replace catch pin (8) and pressure spring (9).

Caution: Note installation position of catch pin (8) (roller horizontal).





Install sealing cap (1) with special tool 23 2 350 in bore bore (2).

Push sealing cap (1) inwards as far as possible.





Install retaining ring (3) and press in with special tool 23 2 350 up to groove.

Check for correct seating of retaining ring (visual inspection).





Install reverse gear switch.

Install spacer (4).

Caution: To prevent damage to drive shaft, attach special tool 23 2 380 to drive shaft while installing retaining ring (3).

Slide retaining ring (3) over special tool 23 2 380 and install in groove.

Retaining ring must be seated without play in groove.

Replace retaining ring with a matching retaining ring.

Retaining rings are available in various thicknesses. Sizes: 2.2 ... 2.6 mm





Coat sealing lip of radial seal with ATF.

Attach special tool 23 2 380 to drive shaft.

Push on radial seal (1) up to housing.





Remove special tool 23 2 380.

Drive in radial seal (1) with special tool 23 2 340 until flush.

Caution: Use plastic hammer to drive in.





Install guide tube.