4-speed gearshift cover for early model years
108 - rod of III and IV gears; 108a - gearshift lever; 109 - locking mechanism; 110 - rod of I and II gears; 111— sealing ring; 112 - reverse gear rod; 112a - reverse gear lever; 114 - Gear shift cover; 116 - breather; 118 - bushing; 119 - needle bearing; 120 - washer; 121 - lock washer; 122 - bolt; 123 - spring washer
Late model year gear shift cover
106 - fork III and IV gears; 107 - fork of I and II gears; 108 - rod of III and IV gears; 109 - locking mechanism; 110 - rod of I and II gears; 111 - sealing ring; 112 - reverse gear rod; 113 - gasket; 114 - Shifter Cover; 115 - hairpin; 116 - breather; 117 - spring washer; 118 - bushing; 119 - needle bearing; 120 - washer; 121 - lock washer; 122 - bolt; 123 - locking or spring washer; 124 - bolt
1. Mark (with a scriber) the position of the gear shift levers relative to the shafts, and then remove them from the splines.
2. Remove the C-rings and washers from the shafts.
3. Remove the shift rods and fingers.
4. Bend back the tab of the lock washer (if it is installed), unscrew the central bolt and remove the locking collar. Fix the relative position of the pin in the cover.
5. Wash all parts in solvent (kerosene) and dry. Conduct defect detection, replace parts if necessary. If the shaft bearings are worn out, press them out with a soft metal punch and install new ones. Replace the sealing rings.
6. Assembly is performed in the reverse order of removal. Pre-lubricate the shafts with transmission oil.
Inspection of crankcases and bearings
[Original published on the website MercedesMan.ru]
Cross section of the speedometer drive mechanism
A - the gap between the speedometer drive shaft and the gearbox cover
1. Check the housings for wear, cracks and damage. Check the bearings for wear by turning them by hand. If they rotate with difficulty or unevenly, replace the bearings.
2. Replace all seals and gaskets. To replace the front cover seal, remove the clutch release bearing guide tube bolts, then press the seal out with a metal pipe. The new seal should be pressed flush with the housing. Lubricate the threads of the guide tube bolts with sealant and install them, but do not tighten them completely until you have reassembled the transmission and installed the clutch housing.
3. To replace the rear cover seal, pry it up with a screwdriver. Press the new seal into place with a hammer and a wooden block until it is flush with the body.
4. Check the speedometer drive gear in the rear cover for wear and replace it if necessary. To remove the wheel, use a soft metal punch to push the shaft through it and the cover. Note that this will also push the sealing ball out (or a cork), which can be pulled out in advance with a screwdriver. Pull out the seal by screwing a bolt into it and pulling it out by the bolt. Install the parts in the reverse order of removal. Before installing the sealing plug, coat it with sealant.