Removing and Installing or Sealing Front Case Section

Removing and Installing or Sealing Front Case Section
- Transmission Removed





- Mount Special Tool 23 0 090 on Special Tool 00 1 490.
- Mount transmission on special tool assembly.
- Drain oil.
- Remove guide sleeve.





- Unscrew backup light switch.
- Remove cap (1).
- Pull Out spring (2) and lockpin (3).
- Check installed position!





- Remove snap ring (4).
- Remove washer (5).

Installation Note: Always replace snap ring.





- Unscrew bolt (6).

Installation Note: Install bolt with a bolt cement**.





- Drive out cylindrical pins.
- Unscrew bolts.

Installation Note: 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 while mounting the front case section.





- Coat case front section with a surface sealing compound in area of the reverse gear shaft. Surface must be cleaned thoroughly and dried of oil.
- Unscrew oil drain plug.
- Install case front section.





- Remove grooved ball bearing for input shaft.

Installation Note:

- Inner race of the grooved ball bearing protrudes.
Install with protrusion face the gear set.





- Unscrew oil drain plug.
Coat sealing surface with surface sealing compound
Sealing surface must be cleaned thoroughly and dried of oil.
Mount front case section and align intermediate shaft through bore
for oil drain plug in such a manner, that roller blearing of intermediate
shaft slides into the bearing shell. Tighten front case section bolts.
Install lockpin and reverse gear switch.





- 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 for as possible.
Protrusion of inner race faces the gear set





- Press grooved ball bearing on input shaft or into front case section with Special tools
23 1 007, 23 1 000 and 23 1 006.

NOTE: Apply Special Tools 23 1 006 in such a manner that flat ends face the input shaft.





- Drive on grooved ball bearing further continuously and simultaneously apply light knocks from a hammer.





- Transmission 260/6 or 260 Sport:
The front case section can not be pressed on due to the uniform thickness of the input shaft.
Double bearing is installed in the front case section.
Heat bearing inner race to about 80° C (175 ° F) with a hot air blower.

Caution: Protect Plastic cage against heat.
Mount front case section, whereby the input shaft must be pulled out.
Tighten front case section bolts.
Tighten torque





Install shim and circlip
Reduce any possible play between the bearing inner race and circlip to
00...0.09mm (0 to 0.0035").