Assembling Transmission - (S5D 200G/ 250G, Only)

Assembling Transmission: - (S5D 200G/ 250G, Only)
Install complete gear train with selector rods in the special tool 23 2 400.





Install reverse gear with collar (2) facing upwards and reverse gear shaft with long extension (1) in special tool 23 2 400. Coat locating face of short extension (3) on reverse gear with Loctite 574 seals compound.





Check end float of the input shaft. Apply special tool 23 2 420 on the input shaft. Insert shim (2) and new circlip (1) in the groove. Check end float with a feeler gauge. End float 0.04 mm.

Note: Shims (2) can be obtained from Parts Service in thicknesses (X) of 2.3...2.65 mm.





Heat input shaft inner bearing race (1) in the front case section to approximately 110...120°C (hot air blower). The heating temperature must be precisely maintained. Check with a thermometer.

Align selector rods with one another. After heating, insert the roller bearing (2) with thick grease into the bearing sleeve with large diameter facing upwards.





Carefully attach the front case section.

Note: The 5th gear synchronizer ring can jam. After completely assembling the transmission, the 5th gear synchronizer ring can be loosened again by twisting the output/input shafts against each other.





Install spacer (5).

Caution: To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft while installing the circlip (6).

Slide new circlip (6) over the special tool 23 2 460 and install in the lower groove.





Install closing ring (4).

Caution: To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft while installing the circlip (3). Slide new circlip (3) over the special tool 23 2 460 and install in the upper groove.





Coat the radial seal sealing lip with ATF-oil. Push radial seal (1) over special tool 23 2 460 up to case. Remove special tool 23 2 460.





Drive in radial seal (1) with special tool 23 2 430. Use plastic hammer to drive in.






Install guide tube. Install screws with Loctite 243 screw locking varnish.
Tightening torque:
M8X22 18 Nm.
M8X30 25 Nm.
M6 10 Nm.





Secure reverse gear shaft in front case section. Install screw (1) with Loctite 243 screw locking varnish and tighten.

Tightening torque:
M8 25 Nm.
M10 45 Nm.

Loosen screw (2) from special tool 23 2 400.





Remove front case section and gear train from special tool 23 2 400 and place to one side with output end uppermost.





Attach 4 rollers to the selector shaft with Vaseline.





Insert selector shaft (1) into front case section. Insert gearshift rail (2) with the opening upward into the case.





Install pivot lever with wider head (1) facing the selector rod (2). Polished side must face towards case. Attach pivot lever with the pin (3).





Install locking pin (1) in the selector rod (2) with Vaseline and secure in the center.





Clean case sealing surfaces and coat with Loctite 574 seals compound. Place retaining plate (1) with flat side uppermost on 2nd gear on countershaft. Screw special tool 23 2 440 into the retaining plate (1)
Install magnetic disc (2) in the case. Align selector rods with one another. Coat locating face of reverse gear shaft (3) with Loctite 574 seals compound.





Lift radial seal on selector shaft out of rear case. Heat inner bearing race (1) and rear case section in area around bearing to 110 ... 120°C (hot air blower). The heating temperature must be precisely maintained. Check with a thermometer.





Insert rear case section up to limit stop. Install 3 screws with new sealing rings. Remove special tool 23 2 440. Screw in fourth screw with new sealing ring. Tighten down all screws.
Tightening torque:M6 10 Nm.





Lightly secure front and rear case sections with opposite two screws. Place rear case section on support 23 0 100 and again lift with the assembly hoist 00 1 490.





Drive in cotter pin (1).





Drive in cotter pin (2).





Screw in all case screws and tighten down. Tightening torque: 22 Nm.





Loosen bolt (1). Install screw (2) with Loctite 243 locking varnish. Tighten the screws (1 and 2).
Tightening torque:
M8 25 Nm.
M8 310Z & 320Z 20 Nm.
M10 45 Nm.





Install radial seal for selector shaft and output shaft. Coat sealing lip with ATF-oil. Push in output shaft radial seal with special tool 24 0 110 and selector shaft radial seal with special tool 23 1 240.

Note: Use a plastic hammer to drive in seal.





Heat output flange to approximately 80°C (hot air blower) and fit to output shaft. Coat thread and locating face of collar nut (1) with Loctite 243 locking varnish. Block output flange using special tool 23 0 020. Tighten collar nut (1) with special tool 23 1 210.

Tightening torque:
Note: Collar nut installed with bolt cement, done in three steps.
Pretension 190 Nm.
Release the tension.
Final tightening 120 Nm.






Install arrester and locking balls.
Order: Locking ball (1), arrester ball (2) and locking pin (3).





Install springs (1) and cylinder pins (2).





Attach cap (1). Install screws with Loctite 243 screw locking varnish and secure.





Install arrester bolt (1) and spring (2).

Note: Roller (3) must be positioned horizontally.





Install shear-off screw (1) with Loctite 243 locking varnish and tighten down. Install the reverse gear switch.



Knock in plug (3).

Install clutch release mechanism