Vehicles after change point in 1982
REMOVING AND INSTALLING/SEALING FRONT
AND REAR TRANSMISSION CASE SECTIONS
Remove transmission - see 23 00 022.
Mount Special Tool 23 0 030 on Special Tool
00 1 490.
Unscrew filler bolt.
Drain oil.
Mount transmission on special tool plate.
Important!
Check grade of oil and volume of oil*.


Siehe auch 23 00 022
Siehe auch * See Specifications
63523030 - click to zoom
 
Remove guide sleeve - see 23 11 622.
Lift out snap ring (4).
Take off washer (5).
Installation:
Always replace the snap ring.


Siehe auch 23 11 622
63523031 - click to zoom
 
Unscrew mounting bolts for sealing cover.

63523032 - click to zoom
 
Punch through middle of sealing cover (7).
Lift out sealing cover (7) with a screwdriver.
Installation:
Replace sealing cover.

63523033 - click to zoom
 
Take off sealing cover.
Important!
Spacer (8).

63523034 - click to zoom
 
Engage 4th gear.
Unscrew bolt (9) while holding the output
flange with Special Tool 23 0 020.
Take off washer (10).
Installation:
Install bolt (9) with a bolt cement.

63523035 - click to zoom
 
Unscrew backup light switch.
Lift out cover (11).
Pull out spring (12) and lockpin (13).
Check installed position.

63523036 - click to zoom
 
Knock back the cylindrical pins.
Unscrew mounting bolts.

63523037 - click to zoom
 
Pull off front case section with Special Tools
23 1 460 and 33 1 301.

63523038 - click to zoom
 
Fourth gear is engaged.
Drive pin (14) out of selector shaft while
counterholding.

63523039 - click to zoom
 
Drive out selector shaft toward the rear.
Radial oil seal (15) will also be pulled out.
Important!
Grooves on selector shaft.
Take off selector arm.
Installation:
Replace radial oil seal.

63523040 - click to zoom
 
Unscrew end cover.
Installation:
Install end cover with a surface sealing
compound.

63523041 - click to zoom
 
Remove three springs.
Remove sealing sap (16).
Installation:
Replace sealing cap.

63523042 - click to zoom
 
Take out 4th gear.
Drive pin (18) out of 3rd/4th gear selector
rod while counterholding.

63523043 - click to zoom
 
Knock out 3rd/4th gear selector rod forward.
Important!
Check lockpin (18).

63523044 - click to zoom
 
Pull retainer (19) off of bearing shaft for
operating lever.

63523045 - click to zoom
 
Push up bearing shaft (20).

63523046 - click to zoom
 
Pull out selector rail (21) forward.
Take off operating lever (22).
Installation:
Mark on operating lever faces up.

63523047 - click to zoom
 
Unscrew bolt (23) for reverse gear shaft.
Installation:
Install bolt with a bolt cement.

63523048 - click to zoom
 
Lift out lockplate.
Apply Special Tool 23 1 200.
Hold output flange with Special Tool 23 0 020.
Unscrew collar nut with Special Tool 23 1 210.

63523049 - click to zoom
 
Pull off output flange with Special Tool
33 1 150.

63523050 - click to zoom
 
Knock back cylindrical pins.
Pull off rear case section with Special Tools
23 1 010 and 33 1 301.

63523051 - click to zoom
 
Installation:
Coat sealing surface with a surface sealing
compound.
Sealing surface must be absolutely clean and
free of oil.
Install roller bearing with the small diameter
end of the plastic cage facing up.
Important!
Bearing shaft (20) for the operating lever must
be installed and the bearing inner race removed
prior to mounting the rear case section.
This requires lifting out the radial oil seal.

63523052 - click to zoom
 
Mount the rear case section.
Center 1st/2nd gear selector rod.
Drive in cylindrical pins.

63523053 - click to zoom
 
Heat bearing inner race (1) to about 80°C
(175°F) with a hot air blower and slide it
onto the output shaft, pressing on with
Special Tool 23 1 160 if necessary.

63523054 - click to zoom
 
Drive in radial oil seal with Special Tools
23 1 380 and 00 5 500.
Lubricate sealing lip with oil.

63523055 - click to zoom
 
Mount the output flange.
Screw on collar nut with a bolt cement.
Apply Special Tool 23 1 200.
Hold output flange with Special Tool
23 0 020 and tighten the collar nut with
Special Tool 23 1 210.
Tightening torque*.


Siehe auch * See Specifications
63523049 - click to zoom
 
Install lockplate.

63523056 - click to zoom
 
Install bolt (23) for the reverse gear shaft with
a bolt cement and tighten to correct torque*.


Siehe auch * See Specifications
63523057 - click to zoom
 
Slide 3rd/4th gear selector rot through the
selector forks.
Install lockpin (18) in selector rod with grease.
Slide in selector rod up to the bore.
Opening in selector rod faces up.

63523058 - click to zoom
 
Insert two locking balls with grease.
Slide in 3rd/4th gear selector rof up to the
lock.

63523059 - click to zoom
 
Arrest Layout:
1 Cap
2 Spring
3 Locking ball
4 Detent ball
5 Lockpin
6 Selector arm
7 Locking pin
8 Spring
9 Locking lever
10 Spring

63023303 - click to zoom
 
Drive 6 x 26 mm pin into the 3rd/4th gear
selector fork while counterholding.

63523060 - click to zoom
 
Install 3 locking balls and 3 springs.
Important!
Check length of springs.
Relaxed length of springs (1) = 20.5 mm
(0.807´´).
Relaxed length of springs (2) = 15.9 mm
(0.625´´).

63523061 - click to zoom
 
Coat cap with a surface sealing compound and
tighten.
Tightening torque*.
Install sealing cap (16) with a surface sealing
compound.


Siehe auch * See Specifications
63523062 - click to zoom
 
Install selector rail (21).
Push up bearing shaft (20) and install operating
lever (22) with mark facing up and toward the
selector rail.

63523063 - click to zoom
 
Position drive shaft vertically.
Slide bearing shaft (20) in direction of the gear
wheel set.
Install retainer (19) with Special Tool 23 1 310.

63523064 - click to zoom
 
Hold 4 rollers in position with grease.

63523065 - click to zoom
 
Insert selector arm.
Slide in the selector shaft.
Important!
The opening in the selector shaft faces selector
rail (21).

63523066 - click to zoom
 
Drive in 6 x 26 mm pin while counterholding.

63523067 - click to zoom
 
Lubricate sealing lip of radial oil seal with oil.
Drive in radial oil seal with Special Tool
23 1 240.

63523068 - click to zoom
 
Coat sealing surface with a surface sealing
compound.
The sealing surface must be absolutely clean
and free of oil.
Heat bearing inner race of input shaft to
about 80°C (175°F) with a hot air blower.
Mount the front case section, while pulling
out the input shaft.
Tighten front case section to correct torque*.


Siehe auch * See Specifications
63523069 - click to zoom
 
Install spacer and circlip.
Reduce any play between the bearing inner
race and circlip to 0 ... 0.09 mm (0 to 0.0035´´).

63523070 - click to zoom
 
Engage 4th gear.
Install washer (10) and bolt (9).
Install bolt with a bolt cement.
Tighten bolt (9) to correct torque* while
holding the output flange with Special Tool
23 0 020.


Siehe auch * See Specifications
63523071 - click to zoom
 
Determine thickness of shim (8) between the
bearing outer race, layshaft and sealing cover.
Measure distance (A) from the bearing outer
race to the case opening for the mounting
tabs.

63523072 - click to zoom
 
Measure wall thickness (B) of the sealing cover.
Measure at the opening for the mounting tab.
Example:
..A = 1.4 mm (0.055´´)
- B = 0.9 mm (0.035´´)
_________________
........0.5 mm (0.020´´) shim thickness

63523073 - click to zoom
 
Hold shim of determined thickness in position
with grease.
Drive in sealing cover (7) with Special Tool
33 4 020 to fit tight.
Important!
Install sealing cover in such a manner, that
wells in sealing cover are aligned with
openings in case.

63523074 - click to zoom
 
Tighten mounting tabs to correct torque*.
Install bolts with a bolt cement.


Siehe auch * See Specifications
63523032 - click to zoom
 
Install locking pin (13), spring (12) and cover
(11).
Check installed position of locking pin.

63523036 - click to zoom