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

23 21 505 Complete Removal And Installation Of Input And Output Shafts- (S5D 200G/ 250G, Only)

Repair With Transmission Removed.





Unscrew drain plug. Drain off fluid. Secure special tool 23 0 100 on the bore of the drain plug. Fit transmission to assembly frame 00 1 490 with special tool 23 0 100.

Removing clutch release mechanism and release lever, refer to 21 51 500.






When fitted: Lift out lockplate (1).





Block output flange using special tool 23 0 020. Unfasten collar nut with special tool 23 1 210.





Pull off output flange.

Note: If ease-of-movement is impaired, remove output flange with special tool 331 150.





Remove radial seal with special tool 00 5 010.





Remove cap (1).





Remove compression springs (1) and cylinder pins (2).





Remove locking stops and ball stops (3) (5 off) with help of a magnet (4).





Note: Note locking pin (1) in the central selector rod!





Locking pin (1) on middle selector rod (2) must locate in center of selector rod.

Note: To secure the position of the locking pin (1), the transmission must be shifted into 2nd gear.





Shift into 2nd gear: Insert splint driver or screwdriver (1) in bore of selector shaft (2). Twist selector shaft (2) up to 1st left detent and press into the transmission.





Unscrew bolts.





Remove sealing ring.





Unfasten screw (1) and reverse gear switch (2). Lever out cap (3).





Remove spring (4) and arrester bolt (5).





Unscrew screws (1 and 2).





Drive dowel pin (1) out towards clutch case with a cotter pin extractor.





Drive out cotter pin (2) with a cotter pin extractor.





Unfasten screws on transmission case (9 off).





Remove transmission from assembly frame 00 1 490 and put down with the output side facing upwards. Fit special tool 23 1 141 together with 23 1 142 and 23 1 143 and install on rear case section. Pull off rear case section.





Remove middle selector rod until all 3 selector rods are at the same height.





Remove retaining plate (1) and magnetic disc (2).





Withdraw pin (3). Remove pivot lever (4). Remove gearshift rail (6).

Note: There are 4 rollers at the lower end of the selector shaft (5) and these can fall out when the selector shaft is removed.

Pull out shift shaft (5).





Position gears and shafts with front case section on special tool 23 2 400.





Unfasten screws and remove guide tube.





Note: Two covered removal holes (1) are located on front end of radial sealing ring.





Screw special tool 23 0 490 into one of the two removal holes. Pull radial sealing ring out of transmission housing with impact weight.





Caution: To avoid damaging input shaft, special tool 23 2 460 must be inserted on the input shaft during removal of the circlip (3).

Lift out circlip (3) and pull off over special tool 23 2 460.





Remove closing ring (4).

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





Lift off circlip (6) and secure to special tool 23 2 460. Pull special tool 23 2 460 with circlip (6) from the input shaft. Lift out shim (5).





Secure special tool 23 1 141 to front case section with 2 screws. Pull front case section from gears and shafts.





Take off needle bearing (1). Remove reverse gear (3) with reverse gear pins (2).








Remove complete gear train with selector rods (1) from special tool 23 2 400.