REPLACING BEARINGS OF ALL TRANSMISSION SHAFTS
- Transmission Removed -
A) Input Shaft, Layshaft in Case Front Section:
Remove case front section 23 11 013.
Knock ball bearing out of and into case with
Special Tools 23 1 190 and 00 5 500.
Important: Install ball bearing that collar faces out.


23 11 013

Pull bearing inner race (1) off of input shaft
with Special Tools 23 1 230 and 00 7 500.

Installation: Heat bearing inner race to about
80°C (176°F) and push on input shaft.
Important: Turning lock!
Pin (2) must engage in opening of bearing inner race.

Knock roller bearing for layshaft in and out
with Special Tools 23 1 220 and 00 5 500.
Protrusion A = approx. 5 mm (0.197´´).
Install roller bearing that open end faces in.

Press bearing inner race (3) off of layshaft with
a screwdriver.

Installation: Knock bearing inner race on layshaft
with Special Tool 23 1 440.
Collar of bearing inner race faces gear.

B) Output Shaft, Layshaft in Case Rear Section:
Remove case rear section 23 11 022.
Remove radial oil seal.
Take off speedometer gear (1), washer (2) and
bearing inner race (3).


23 11 022

Unscrew bolts.
Take off bearing bracket.
Important: Shim!

Knock out ball bearing with Special Tools
23 1 080 and 00 5 500.

Knock in ball bearing with Special Tools
23 1 410 and 00 5 500.
Attach bearing bracket.

Pull ball bearing inner race off of output shaft
with Special Tools 23 1 100 and 00 7 500.

Installation: Heat ball bearing inner race to
about 80°C (176°F) and push on output shaft.
Important: Turning lock!
Opening of bearing inner race must engage in ball.
Draw reference line (1) to facilitate installation
of bearing race.

Heat case rear section to about 80°C (176°F).
Remove roller bearing (2).
Installation: Install bearing with large diameter
end facing up.

Knock in roller bearing with Special Tools
23 1 390 and 00 5 500.

Bearing inner race (3) can only be pulled off
together with 5th gear (see 23 21 503).


23 21 503

Knock new bearing inner race on layshaft with
Special Tool 23 1 030.
Collar of bearing race faces gear.

C) Output Shaft, Layshaft in Intermediate Case:
Remove input and output shaft 23 21 503.
Knock roller bearings for input shaft and layshaft
out of intermediate case with Special
Tools 23 1 130 and 00 5 500.
Important: Loosen and turn oil plate (1) for
roller bearing of output shaft.


23 21 503

Knock roller bearings for output shaft and
layshaft into intermediate case with Special
Tools 23 1 410 and 00 5 500.
Knock in roller bearings flush.

Tighten oil plate (1) in vertical position.

Check condition of bearing inner race (2),
replacing if necessary.
When replacing, press gears off of output shaft
(see 23 21 554).


23 21 554

Vehicles after change point in 1982
REPLACING BEARINGS OF ALL
TRANSMISSION SHAFTS
- Transmission Removed -
Remove input and output shaft assembly
23 21 503.
A) Input Shaft, Layshaft in Front Case
Section:
Input Shaft:
Drive out grooved ball bearing with Special
Tools 23 1 480 and 00 5 500.
Installation - see 23 11 013.


23 21 503
23 11 013

Transmission 260/6:
Drive out double bearing with Special Tools
23 1 410 and 00 5 500.

Transmission 260/6:
Heat front case section in area of bearing to
about 80°C (175°F) with a hot air blower.
Important!
Install bearings with rollers facing gear set,
driving in to fit tight with Special Tools
23 1 470 and 00 5 500 if necessary.

Layshaft:
Loosen circlip (1) with one knock from
Special Tools 23 1 270 an 00 5 500.

Lift out circlip (2).
Remove spacer (3).

Drive out bearing shell with Special Tools
23 1 270 and 00 5 500.

B) Output Shaft, Layshaft in Rear Case Section:
Output Shaft:
Unscrew bolt (1).
Coution!
Spring force.
Remove spring (2).
Installation:
Install bolt with Loctite No. 270.

Install Special Tool 23 1 250 for removal of
the selector arm.

Remove socket head bolt (3).
Installation:
Install bolt with Loctite No. 270.
Tightening torque*.


* See Specifications

Remove selector arm from above
Important!
Roller.

Installation:
Insert selector arm with Special Tool 23 1 250.
Swing out selector arm with roller over locking
lever (4).

Position end of spring (3) above high spot.
Press (don´t knock) down selector arm in this
position.
Mount selector arm with socket head bolt
before removing the special tool.
Install socket head bolt with Loctite No. 270.
Tightening torque*.


* See Specifications

Remove bearing holder (5).
Important!
Don´t unscrew bolt (6).
Locking lever (7) remains on bearing holder.

Installation:
Check installed position of locking lever (7)
and thrust pin (8).

Lift out radial oil seal.
Drive out grooved ball bearing with Special
Tools 23 1 120 and 00 5 500.
Important!
Spacer X.

Determine thickness of spacer X.
Measure distance (A).

Measure distance (B).
Example:
..A ....20.3 mm (0.799´´)
- B ....20.0 mm (0.787´´)
___________________
..X ......0.3 mm (0.012´´) spacer thickness

Heat rear case section in area of grooved ball
bearing to about 80°C (175°F) with a hot
air blower.
Install spacer X.
Install grooved ball bearing.
Important!
Inner race of grooved ball bearing has
protrusion.
Install bearing race that this protrusion faces
the gear set.
If necessary, drive in bearing against stop with
Special Tool 23 1 470.

Transmission 260/6:
Split Bearing Inner Races:
The bearing inner race with an opening for the
ball (truning lock) must be mounted on the
output shaft (see "Replacing Output Shaft -
23 21 554).


23 21 554

Layshaft:
Apply large end of Special Tool 23 1 280 in
bearing shell.

Apply Special Tool 33 4 020.
Screw on Specila Tool 23 1 300.
Pull out bearing shell.

Drive in bearing shell with Special Tools
23 1 260 and 00 5 500.

Check axial play of layshaft.
Install circlip (2).

Install old spacers.
Drive in bearing shell to fit tight in front case
section with Special Tools 23 1 260 and
00 5 500.
Important!
Oil groove must be aligned with groove in case.

Place layshaft with roller bearings in rear case
section.

Install case front section and mount with two
bolts opposite each other.
Center case front section with dowel pins
slightly.
Unscrew oil filler plug (1).

Install dial gage with holder.
Tip of dial gage must bear on tooth of
layshaft.

Check layshaft axial play through bore for oil
filler plug.
Axial play = 0.13 to 0.23 mm (0.005 to 0.009´´).
If correction is necessary, bearing shell must be
removed again and a spacer of different thickness
installed.

Install gear set.
Determine thickness of drive pinion shim.
Install old shim and circlip.
Adjust play to 0 ... 0.09 mm (0 to 0.0035´´).
Determine thickness of spacer for guide sleeve
(see 23 11 623).


23 11 623