Removing and Installing Input and Output Shaft Assembly
Removing and Installing Input and Output Shaft Assembly
- Transmission Removed -
Remove transmission
Remove transmission case front section 23 11 013.
Remove 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.
Version with integrated Vibration Damper:
Hold output flange with Special Tool 23 1 320.
Pull off output flange with Special Tool 33 1 150.
Unscrew bolt (1).
Remove holder (2).
Unscrew bolt (3).
Remove shaft with reverse gear and needle bearing.
Pull out pin (4) for operating lever (5).
Pull out selector rail (6).
Remove operating lever (5).
Note: Install operating lever that notch faces up and in direction of the selector rail.
Engage 4th gear
Drive in pin (7), while counterholding.
Note: Only drive in pin (7) far enough that selector
shaft can be pulled back and out.
Radial oil seal (8) will also be pulled out.
Note: Rollers on selector shaft.
Installation
Replace radial oil seal.
Remove selector arm.
Detach end plate.
Installation:
Install end plate with sealing compound
Sealing surface must be cleaned thoroughly and dried of oil.
Remove end plate (9).
Installation
Replace end plate.
Remove 3 spring and 3 ball.
Note: Springs differ in length (see installation).
Drive out pin (10) in 3rd/4th gear selector fork.
Installation
Replace pin.
Knock out 3rd/4th gear selector for forward.
Note: Lockpin (11) in selector fork.
Engage 2nd and reverse gears by pushing 1st/2nd and 5th/reverse gear
selector rods forward.
Press input shaft output shaft and layshaft out of case rear section with Special tool 23 1 050.
Note: To avoid damage on sealing surface, use a piece of wood, aluminum or similar material between claws and sealing surface.
Note: be careful not to clamp selector rods and layshaft while pressing out parts. Layshaft must not tilt off in this step.
Installation:
Check condition of all bearings, replacing if necessary.
Installing:
Install 3rd/4th gear selector fork and 1st/2nd as well as 5th/reverse gear selector rods with selectors forks.
check thrust washer (1) (only for 260/5).
Remove all detent and locking balls from case rear section.
Install roller bearing with large diameter facing out.
Lubricate lockpins and locking levers with oil.
Transmission 260/6:
The radial oil seal for the output flange and the ball bearing inner race must be removed prior to installation of the input and output shafts.
Heat grooved ball bearing inner race in rear case section to about 80 ° C (175°F) with hot air blower.
2nd and reverse gears are engaged.
Install input shaft, output shaft and layshaft in rear case section.
Align shift rods.
Pull input shaft, output shaft and layshaft into rear case section with Special Tolls 23 1 300 and 23 2 150
Note: Make sure shift rods and layshaft are not clamped while pulling in.
Note: Screw Special Tool 23 1 301 between both above mentioned special tools for the version with a longer output journal.
260/6 Transmission:
Install input shaft and output shaft with 3rd/4th gear shift forks and 1st/2nd and 5th/reverse gear shift rods or layshaft in the rear case section.
Heat bearing inner race (1) to about 80°C (175°F) with a hot air blower and slide it on the output shaft, pressing on with Special Tool 23 1 160 if necessary.
Drive in radial oil seal flush with Special Tool 23 1 370.
Lubricate sealing lip with oil.
Move shift rods into neutral position.
Push 3rd/4th gear shift rod through the shift forks
Place lockpin (1) in the shift rod with grease.
Push in shift rod up to the bore.
Opening on shift rod faces up.
Insert two locking balls with grease.
Push in 3rd/4th gear shift rod up to the arrest.
Arrest Assembly:
- Cap
- Spring
- Dentent ball
- Locking ball
- Lockpin
- Selector arm
- Lockpin
- Spring
- Locking lever
- Spring
Drive 6 x 26 mm pin into 3rd/4th gear selector fork (counterhold).
Install 3 locking balls and 3 springs.
Note: Version with Different Length Springs: Install short spring (1) with relaxed length (A) = 15.9 mm (0.626") for 5th/reverse gear selector rod.
Install end cap after coating with sealing compound
Install end cover with sealing compound
Drive pin out of selector arm.
Hold 4 rollers in position with grease.
Slide in selector shaft and install selector arm (1) at same time.
Note: Opening in selector shaft faces out
Drive in 6 x 26 mm pin (counterhold)
Lubricate sealing lip radial oil seal with oil
Drive in radial oil seal with Special Tool 23 1 240
Install selector rail.
Groove (1) in selector rail faces up.
Install operating lever (5) with notch facing up and toward selector rail.
Install pin (4).
Coat case rear section in area of reverse gear shaft with sealing compound
Surface must be cleaned thoroughly and dried of oil.
Install shaft with needle bearing and reverse gear.
Mount shaft with bolt (3)
Install bolt with a bolt cement
Insert holder (2), press out and secure in this position.
Install output flange.
Install collar nut with a bolt cement
Hold output flange with special Tool 23 0 020
Tighten collar nut with Special Tool 23 1 210
Tighten torque
Version with Intergrated Vibration Damper
Hold output flange with Special Tool 23 1 320
Install lockplate