Vehicles after change point in 1982
REMOVING AND INSTALLING INPUT AND
OUTPUT SHAFT ASSEMBLY
- Front and Rear Transmission Case
Sections Removed -
Clamp Special Tool 23 0 080 in a vise.
Take intermediate case with gear wheel set
off of Special Tool 23 0 030 and mount it
on Special Tool 23 0 080.
Pull off the 5th gear wheel.
Pulling-off force*.


Siehe auch * See Specifications
63523079 - click to zoom
 
Important!
Always make sure that there is play (S)
between the 3rd gear wheel and layshaft
while pulling off the 5th gear wheel, to avoid
damaging the 3rd gear wheel:
If necessary, push up the output shaft.

63523080 - click to zoom
 
Mount intermediate case with gear wheel set
on Special Tool 23 0 030 again.
Pull bearing inner race off of the output shaft
with Special Tools 23 1 100 and 00 7 500.
The pulling hooks must be modified to fit in
the slots.

63523081 - click to zoom
 
Take off washer (1) and ball (2).

63523082 - click to zoom
 
Pull off 5th gear wheel with synchromesh ring
and split needle bearing.

63523083 - click to zoom
 
Lift out circlip (3).
Installation:
Replace circlip.

63523084 - click to zoom
 
Pull off reverse gear wheel with guide nut and
selector rod with Special Tool 23 1 050.

63523085 - click to zoom
 
Take guide sleeve with selector fork and
selector rod, synchromesh ring, reverse gear
wheel and needle bearing off of the output
shaft.
Important! - Installation:
The stepped end of the sliding sleeve faces
the reverse gear wheel.

63523086 - click to zoom
 
Pull input shaft, output shaft with 1st/2nd
gear selector rod, 3rd/4th gear selector fork
and layshaft out of the intermediate case.

63523087 - click to zoom
 
Take selector rod with 1st/2nd gear selector
fork and 3rd/4th gear selector fork off of the
gear wheel set.

63523088 - click to zoom
 
Installation:
Install input shaft, output shaft with 1st/2nd
gear selector rod and layshaft in the intermediate
case.

63523089 - click to zoom
 
Install needle bearing, reverse gear wheel and
synchromesh ring on the output shaft.

63523090 - click to zoom
 
Install guide sleeve with sliding sleeve and
selector rod with 5th/reverse gear selector
fork on the output shaft.
Important!
Stepped end of sliding sleeve faces the reverse
gear wheel.

63523091 - click to zoom
 
Drive on guide sleeve with light knocks from
Special Tool 23 1 290.
Important!
The tabs on the synchromesh ring must be
aligned with openings in the guide sleeve.

63523092 - click to zoom
 
Shift the sliding sleeve in direction of the
reverse gear wheel.
Remove all play on guide sleeve with circlip (3).
Circlips are available from Parts in different
thicknesses from 1.7 to 2.0 mm (0.067 to
0.079´´).
Install circlip (3).

63523093 - click to zoom
 
Install the synchromesh ring and 5th gear
wheel.

63523094 - click to zoom
 
Take intermediate case with gear wheel set off
of Special Tool 23 0 030 and mount it on a
press.
Lubricate pressing surface of layshaft with oil.
Heat 5th gear wheel uniformly to 150°C
(300°F), checking temperature with a
thermochrome pencil.
Mount the 5th gear wheel on the layshaft and
press it on to fit tight with Special Tool
23 1 430.
Pressing-on force*.


Siehe auch * See Specifications
63523095 - click to zoom
 
Important!
Lift and turn the 5th gear wheel until the
teeth mesh.

63523096 - click to zoom
 
Install split needle bearing.
Install ball (2) with grease.
Slide on washer (1).

63523082 - click to zoom
 
Installation:
Heat the ball bearing inner race to about 80°C
(175°F) with a hot air blower and slide it onto
the output shaft.
Important!
Turning lock - opening in bearing inner race
must engage on ball.
Draw line (1) to make installation of the
bearing race easier.

63523097 - click to zoom
 
Install the 3rd/4th gear selector fork.

63523098 - click to zoom