Replacing All Transmission Bearings

Replacing bearings on all gearshafts. (S5D 20OG/250G)

Transmission removed.
Removing input and output shafts, refer to Disassembly and Assembly.





Output shaft bearings in rear case:
Place rear case section on support 23 0 100 and lift with assembly hoist 00 1 490.





Unfasten screws.
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 approx. 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 locking varnish and screw into place.
Tightening torque, refer to Manual Transmission/Transaxle, Specifications.





Bearing on the 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 too! 00 7 500 / 23 1 250 on a hydraulic press.





Note: The taper (2) on the 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, refer to Manual Transmission/Transaxle, Specifications.





Output shaft bearings 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.





Outer bearing 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 out bearing shell.






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





Push in bearing shell (1) insert 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, refer to Manual Transmission/Transaxle, Specifications.
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 547 gasket compound.
Use suitable gasket 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.