REMOVING AND INSTALLING/SEALING TRANSMISSION
CASE FRONT SECTION
Remove transmission 23 00 020.
Detach rubber mount.
Mount transmission on Special Tools 23 0 070
and 00 1 490.
Drain oil


23 00 020

Pull off wires on backup light switch.
Detach wire harness at suspension.

Detach console.

Engage 3rd gear.
Push back sleeve (1).
Knock out cylindrical pin (2).
Pull off selector rod.

Unscrew backup light switch.
Detach guide flange.
Important: Watch length of bolts.
Bolts (1 ... 3) = 8 x 30 mm
Bolts (4 ... 7) = 8 x 22 mm
Install bolts with Loctite No. 573.

Remove guide flange.
Important: Coat sealing surfaces with Loctite
No. 270.
Sealing surfaces must be absolutely clean and
free of oil.

Remove circlip (1).
Remove slotted washer (2).
Installation: Install slotted washer that slot
faces circlip.

Remove circlip (3).
Remove washer (4).

Remove cover (5).
Remove spring (6) and lockpin (7).
Installation: Watch installed position.

Knock out cylindrical pin.
Unscrew bolts.

Pull off transmission case front section with
Special Tools 23 1 170 and 33 1 301.

Coat sealing surfaces with Loctite No. 573.
Sealing surfaces must be absolutely clean and
free of oil.
Attach transmission case front section.

Install lockpin and backup light switch.
Arrangement of Lockpin.

Heat ball bearing inner race (8) to about 80°C
(176°F) and push on input shaft.
Pull out input shaft for this job.

Take up play between washer (4) and circlip (3).
Circlips (3) are available in different thicknesses
from Parts.
Install slotted washer and circlip.

Take up play of grooved ball bearings on input
shaft and layshaft to guide flange.
Distance A = 7.8 mm (0.307´´) - input shaft
Distance B = 4.3 mm (0.169´´) - layshaft

Measure distances C and D.
Distance C = 8.1 mm (0.319´´) - input shaft
Distance D = 4.8 mm (0.189´´) - layshaft
Input shaft:
C 8.1 mm (0.319´´)
- A 7.8 mm (0.307´´)
-------------------------------
0.3 mm (0.012´´) shim thickness

Layshaft:
D 4.8 mm (0.189´´]
- B 4.3 mm (0.169´´)
-------------------------------
0.5 mm (0.020´´)
- 0.1 ... 0.2 mm (0.004 ... 0.008´´) play
----------------------------------------------------
0.3 ... 0.4 mm (0.012 ... 0.016´´) shim
Hold shims in position with grease.
Attach guide flange.

Vehicles after change point in 1982
REMOVING AND INSTALLING/SEALING
TRANSMISSION CASE FRONT SECTION
Remove transmission 23 00 022.
Mount Special Tool 23 0 090 on Special Tool
00 1 490.
Mount transmission on special tool assembly.
Drain oil.


23 00 022

General Information:
A stronger five speed overdrive manual transmission,
Type 260/6, is installed since 9.85 in
cars with a 3.2 or 3.4 liter M 30 engine.
It can be identified on the additional cooling
ribs on the bottom of the case.
The 260/6 overdrive transmission has been
included in the following description for the
formerly installed Type 260/5 overdrive
transmission.

Remove guide sleeve 23 11 623.
Unscrew backup light switch.
Remove cap (1).
Pull out spring (2) and lockpin (3).
Check installed position!


23 11 623

Remove snap ring (4).
Remove washer (5).
Installation:
Always replace snap ring.

Unscrew bolt (6).
Installation:
Install bolt with Loctite No. 270.
Tightening torque*.


* See Specifications

Drive out cylindrical pins.
Unscrew bolts.
Installation:
Check length of bolts.
Bolt (1) = 8 x 60 mm

Pull off front case section with Special Tools
23 1 460 and 33 1 301.

Install roller bearing on layshaft that small
diameter end faces up.
Note:
Coat rollers with grease and press in, in order
to avoid clamping of rollers when mounting
the case front section.

Coat case front section in area of reverse gear
shaft with Loctite No. 573.
Surface must be thoroughly cleaned and dried
of oil.

Remove grooved ball bearing for input shaft.
Important!
Inner race of grooved ball bearing has a
protrusion.
Protrusion faces gear shaft.

Unscrew oil drain plug.
Coat sealing surface with Loctite No. 573.
Sealing surface must be thoroughly cleaned
and dried of oil.
Mount front case section.
Align layshaft through bore for oil drain plug
that roller bearing of layshaft slides into
bearing shell.
Bolt front case section.
Tightening torque*.
Install lockpin and reverse gear switch.


* See Specifications

Heat* bearing inner race and front case section
in area of grooved ball bearing with a hot air
blower.
Push on grooved ball bearing as far as possible.
Inner race protrusion faces gear set.


* See Specifications

Press grooved ball bearing on to input shaft
and into front case section with Special Tools
23 1 007, 23 1 000 and 23 1 006.
Important!
Insert Special Tools 23 1 006 that flat sides
face input shaft.

Keep driving on grooved ball bearing
simultaneously with light hammer knocks.

Transmission 260/6:
The front case section cannot be pressed on,
because of the uniform thickness of the input
shaft.
A double bearing is installed in the front case
section.
Heat bearing inner race to about 80°C (175°F)
with a hot air blower.
Important!
Protect plastic cage against heat.
Mount front case section, pulling out the input
shaft for this purpose.
Bolt front case section.
Tightening torque*.


* See Specifications

Install spacer and circlip.
Adjust plat between bearing inner race and
circlip to 0 ... 0.09 mm (0 to 0.0035´´).