S5D 250G Transmission

Replacing Bearings on All Gearshafts (S5D 20OG/ 250G)



Preparation
- Transmission removed.
- Remove input and output shafts.





Bearing Of Output Shaft In Rear Case Section:

Place rear case section on support 23 0 100 and lift with assembly hoist 00 1 490.





Unscrew bolts. If installed, remove oil deflector plate (1).

Remove retaining plate (2).





Remove output shaft bearing with special tool 23 1 340 and handle 00 5 500 from the outside to the inside.





Heat the rear case section in the area near the output shaft bearing to approximately 80°C (hot air blower).

Install bearing, using, if necessary, special tool 23 2 450 and handle 00 5 500 until securely driven into place.





Clean screws and threaded bores.

Install retaining plate (2) and oil scraper plate (1).

Coat screws with Loctite 243 screw locking varnish and screw in.
Tightening Torque, retaining plates for bearings: M6 10 Nm.





Bearing On Countershaft:

^ Hex screw with washer Clamp the layshaft bearing in a vise with two protective pads (3).

Note: Screw (1) has a left-hand thread.

Unscrew bolt (1).
Take off washer (2).

Note: Instead of the hex screw (1) and the washer (2), a Torx screw is fitted!





^ Torx screw Clamp countershaft in a vise with protective jaws.

Note: Screw (1) has a left-hand thread.

Unscrew bolt (1).





Press bearing (2) off countershaft with a special tool 23 1 250 on a hydraulic press.





Press inner bearing race (3) off countershaft with special tool 00 7 500 / 23 1 250 on a hydraulic press.





Note: Taper (2) on outer bearing race must point upwards.

Press new bearing (1) off countershaft with special tool 23 1 040 on a hydraulic press.





Clamp countershaft in a vise with protective jaws.

Screw in new Torx screw (1) and tighten down.
Tightening Torque, bearing on countershaft M10 90 Nm.

Bearing Of Output Shaft In Front Case Section:





Remove selector arm (1). For this purpose, unscrew screws (4 and 5).

Remove bracket (3), spring (2) and selector arm (1).

Remove retaining plate (6).





Remove output shaft bearing with special tool 23 1 340 and handle 00 5 500 from the outside to the inside.





Heat the front case section in the area near the bearing to approximately 80°C (hot air blower).

Install bearing, using, if necessary, special tool 23 1 470 and handle 00 5 500 until securely driven into place.

Bearing Outer Race Of Countershaft In Front Case Section:





Insert special tool 23 1 280 into the bearing shell (1).





Apply Special tool 33 4 020.

Screw on Special tool 23 1 300.

Pull bearing shell out.





Installation:
Insert bearing shell (1) that the slot in the bearing shell is aligned with beads (2) (turning lock) in the case.





Push in bearing shell (1) with special tool 23 1 260 and handle 00 5 500. Locking device (2).





Install retaining plate. For this purpose, push locking bolt (2) outward with a screw (1).

Push the locking bolt (3) outward with a screwdriver (4).

Install retaining plate and secure with screws. Install screws with Loctite 243 screw locking varnish.
Tightening Torque: M6 10 Nm.

Remove screw (1).





Note installation position of the pressure pin. Beveled sides must face each other inwards.





Install roller (1) with selector arm (2).





Install spring (4) and sleeve (1).

Position shorter leg (K) on case and longer leg (L) in the slot on selector arm.

Coat screw-head (2) contact surface with Loctite 574 seals compound.





To ease assembly (strong spring force), insert special tool 23 1 250 in the selector arm and push sleeve (1) up to the case.

While in this position, install screw (2) with Loctite 243 screw locking varnish and attach loosely.

Then install screw (3) with Loctite 243 screw locking varnish and secure.

Tighten screw (2) last.