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Transmission, Seal Completely
The sealing operations are to be carried out with the
transmission housing installed.
a) Seal Ring for Helical Gear of Speedometer (Driven),
Replace up to Transmission A 355 - 3 - 1
Unbolt speedometer cable (1) from guide piece.
If present:
Disconnect wiring harness plug (2) for odometer frequency
sensor.
Remove helical gear of speedometer.
Unscrew retaining plate.
Use screwdriver to pry out guide piece.
Replace seal ring and rubber O-ring.
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Assemble and install helical gear of speedometer.
Tighten down retaining plate - 4 Nm/3 lbf. ft.
Coat splines of helical gear with Antifriction Bearing Grease
19 41 574 (90 001 812).
Tighten speedometer cable or connect wiring harness plug for
odometer frequency sensor.
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Seal Ring for Speedometer Helical Gear (Driven), Replace
as of Transmission A 356 - 3 - 1
Unbolt speedometer cable (1) and/or wiring harness plug for
odometer frequency sensor (2).
Remove bolts for guide piece.
Lever out guide piece from transmission housing.
Lever out O - ring from groove.
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Fit new O - ring into groove.
Coat splines of speedometer helical gear with Antifriction
Bearing Grease 19 41 574 (90 001 812).
Place guide piece into transmission housing.
Tighten bolts (3) for guide piece (1) into transmission
housing, 4 Nm/3 lbf. ft.
Fasten speedometer helical gear and/or connect wiring
harness plug for odometer frequency sensor.
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b) Seal for Shift Cover, Replace
Remove cardan joint pin from shift linkage.
UP to MY '90:
Remove retaining clip from pin (arrow).
Push pin (arrow) out of cardan joint.
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As of MY '91:
Press expanding springs (1) of hollow pin together with
pliers and push pin out of cardan joint (arrow).
Replace pin after removal.
On all models:
Remove plug from adjustment bore hole and insert
KM - 527 or KM - 527 - A.
If using KM - 527, grind off approx.
3 mm/0.12 in. of chamfer on short leg. KM - 527 - A
has been modified.
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Unscrew shift cover from transmission housing and remove
(arrows).
Stick new gasket to transmission housing with Antifriction
Bearing Grease. 19 41 574 (90 001 812).
Important:
Bolt cover in place on the transmission housing only after the
end shield (pos. C) has been installed.
If the seal ring of the shift rod must be replaced, disassemble
and assemble cover - see corresponding operation in section "Manual
Transmission und Differential, Overhaul".
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c) Seal for End Shield, Replace
Remove
Raise vehicle. Unscrew cap or end shield cover from end
shield.
Unscrew fillister head screw from drive shaft.
Remove retaining ring beforehand (arrow).
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Remove transmission drive shaft using
KM - 556 - 1 - A (was
KM - 449 - 1 in conjunction with Kukko Support
22 - 1).
The splines for the clutch are disengaged. For this reason the
clutch is not to be disengaged after this point.
Unscrew reversing lamps switch.
Unbolt end shield from transmission housing.
Withdraw end shield with main shaft and drive shaft from
transmission housing.
Important:
Fluid will drain out.
Replace end shield seal.
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Install
Bolt end shield into transmission housing and tighten to
prescribed torque - 22 Nm/16 lbf. ft.
Stick new seal to transmission housing with Antifriction Grease
19 41 574 (90 001 812).
Stick magnet and spacer washer for reverse idler shaft with
antifriction grease in end shield.
Screw on reversing lamps switch - observe prescribed torque
- 20 Nm/15 lbf. ft.
By hand carefully insert transmission drive shaft into
splines of clutch disc and gear cluster.
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Screw fillister head screw into transmission drive
shaft and, using KM - 564 (2), drive the shaft up to stop in
gear cluster.
On 4-speed manual transmission use three spacer sleeves (1).
Secure drive shaft with new retaining ring.
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Install the screw cap in bearing cover oil-tight with
Sealing Compound 15 03 166 (90 094 714) or PVC tape
4-speed: 50 Nm/37 lbf. ft., 5-speed up to Model Year
88 ½: 30 Nm/22 lbf. ft.
After the cap has been tightened, the distance between the
front of the cover and the surface of the end shield must not exceed
4 mm/0.16 In. This ensures a definite sealing screw depth.
For 5-speed as of Model Year '88 ½: tighten end shield
cover to end shield - M 7 x 1: 15 Nm/11 lbf. ft., M 8 x
1.25: 20 Nm/15 lbf. ft.
Bolt shift cover to transmission housing
(arrows) - 15 Nm/11 lbf. ft.
Measurement required, see "Shift Cover, Assemble and
Install".
Adjust shift linkage (see operation in this group).
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Mount cardan joint.
Up to MY '90:
Insert pin and secure with clamp.
As of MY '90:
Press in new pin to stop (arrow), so that the expanding
springs (1) engage.
On all models:
Coat pin of cardan joint with Silicon Grease
19 70 206 (90 167 353).
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d) Seal for Differential Cover, Replace
Unbolt cover for differential from transmission housing.
Important:
Fluid will drain out.
Replace seal for cover.
Bolt cover onto transmission housing - observe prescribed
torque - 30 Nm/22 lbf. ft.
Stick new seal to cover with Antifriction Bearing Grease
19 41 574 (90 001 812).
Top up transmission fluid at bleeder screw in shift cover
until it flows out at oil check bore hole.
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e) Seal Rings for Axle Shafts on Differential, Replace
Both
Remove both front wheels.
Unbolt swivel joint on both sides from steering knuckle and
remove from steering knuckle.
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Using KM-460-2-A (left side, modified tool) and
KM-460-1 (right side), drive both axle shafts out of transmission
housing.
Important:
The chamfered side of the tool must always face the
transmission.
Note: Fluid runs out.
Immediately suspend axle shaft, do not allow to sag.
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Note:
If the axle shaft catches in exceptional cases while being
removed and cannot be driven out of the transmission housing, place suitable
drift between the axle shaft end and the bevel gear shaft and drive out axle
shaft. To do this, remove cover for differential (fluid runs out).
Using KM - 557 (was Kukko Extractor 21/6 in
conjunction with Kukko Support 22-2), pull each seal ring from the
transmission housing or bearing ring.
Using KM - 446 drive each seal ring flush into
transmission housing or bearing ring.
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First push both axle shafts into the transmission housing.
Then drive in with suitable drift until retaining ring
catches.
Position drift on bead of welded seam (do not position on sheet
metal panelling).
Beforehand, seat new retaining ring in axle shaft.
Important:
Do not overstress retaining ring.
When the retaining ring snaps into place, check that it is
seated properly by pulling on the outer diameter of the joint.
Important:
Seating of the axle shaft cannot be checked by pulling
on the shaft.
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Secure swivel joint to steering knuckle with bolts and nuts
- important mounting part.
Observe prescribed torque 30 Nm/22 lbf. ft.
Insert bolt (arrow) from rear to front - viewed from rear to
front of vehicle.
Use new self-locking nut.
Tighten down wheel bolts alternating clockwise -
110 Nm/81 lbf. ft.
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