Disassembling transmissions

Overhaul instructions

Applies to: 1998–2004; M5M42

Special tools: 999 2520, 999 5321, 999 5477

General

Place the transmission on stand 999 2520 with transmission fixture 999 5321.

Remove:

• the guide bushings if applicable
• the front engine mounting (1).

Install stand 999 5321 for the transmission by using two 30 mm long m10x 1.50 screws.

Position the transmission on stand 999 2520.

Preparations

Release the bearing, fork and rubber cover (1).

Remove:

• the drain plug
• the filler plug
• the temperature switch (2)
• the engine pad on the transmission side (3)
• the gear selector arm (4)
• the mounting for the gear selector cable (5).

Removing the guide bushing for the input shaft

Remove:

• the screws
• the guide bushing.

Removing the gear selector unit

Remove:

• the mounting for the gear selector cable (A)
• the sealing screw and seal ring (B)
• unscrew and unthread the transmission housing from the transmission.

Carefully remove the entire mechanism.

Removing the tension screws and the back-up lamp switch from the transmission

Clean the surrounding area.

Remove:

• the screws (1) and the seal rings
• the switch (2) for the back-up (reversing) lamp.

Removing the protective plate for the back-up gear

Clean the area around the protective plate.

Remove:

• all screws
• the protective plate. Use special tool 999 5477.

Removing the back-up gear cog

Remove the mounting screws and the sealing ring from the back-up gear cog.

Turn the cog to remove it.

Removing the side protection plates from the transmission

Clean the area around the side protection plate.

Insert a screwdriver under the protection plate. Remove the protection plate.

Disassembling the transmission housing and clutch housing

Remove all remaining screws (two screws from the clutch side).

Pull out the snap ring to remove it through the bearing groove.

Separate the transmission housing from the clutch housing. Remove the transmission housing.

Remove the magnet from the transmission housing.

Removing primary, secondary and gear selector shafts and the differential

Remove the screws and holder for the secondary shaft.

Lift out all the shafts at the same time and place them to one side.

Remove the differential (the final drive gear) from the clutch housing.