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W123 (1976-1985) W124 (1984-1995) W210 (1996-2002)
  • Main
  • E-Class
  • W123 (1976-1985)
  • Transmission
  • Mechanical gearbox
  • Assembly of four-speed and five-speed gearboxes

Assembly of four-speed and five-speed gearboxes (Mercedes-Benz E-Class W123)

0
1. Using a drift, press the speedometer drive worm gear onto the secondary shaft so that its chamfered end faces rearward.

2. Install the rear cover with a new gasket and the correct torque, tighten the bolts evenly.

3. Press the secondary shaft flange onto the secondary shaft splines. Secure it with a nut, tightening it to a torque of 15.0 kgf·m, holding the flange with a metal rod secured to it with a bolt. If provided, lock the nut by caulking its flange into the groove.

4. Install the front cover together with the adjusting shims and sealing gasket and tighten the bolts. If the primary shaft bearing has been replaced, adjust the end clearance of the bearing outer ring within 0.0-0.05 mm. If the intermediate shaft bearing has been replaced, adjust the end clearance of the bearing outer ring within 0.07-0.15 mm. To determine the clearance, measure the distance from the cover shoulders, bearing ring or bearing retaining ring to the mating surface with a vernier caliper, but add the thickness of the compressed sealing gasket to the cover dimensions. The threads of the cover bolts should be lubricated with sealant.

5. Place the shift forks and the reverse and 5th gear selector rod in neutral position, then push the reverse and 5th gear selector rod approximately 25.00 mm through the cover.

6. Install the gearshift cover with a new sealing gasket, simultaneously engaging the reverse and 5th gear engagement pin with the lock and the shift forks with the rods. Lubricate the bolt threads with sealant, screw them in and tighten them.



7. Place the washer on the reverse and 5th gear engagement rod and install the snap ring.

8. Press the gear shift lever onto the splines in the position noted earlier and tighten the tie bolt.

9. Fill the gearbox with oil up to the bottom edge of the filler neck and tighten the plug.

10. Install the release lever and clutch bearing.
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The article has been verified: Levin Kirill Glebovich
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E-Class W123 / Mechanical gearbox
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Assembly of a five-speed gearbox
Assembly of a four-speed gearbox
Gearbox assembly
Disassembling and assembling the gearshift cover
Disassembly and assembly of the secondary shaft
Adjusting the gear shift drive (from the lever on the body floor tunnel)
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W210 (1996-2002) 
  • General information
  • Vehicle description
  • Working conditions and tools
  • Car care
  • Diesel engines
  • Engine repair
  • Lubrication system
  • Cooling system
  • Injection system
  • Supply system
  • Exhaust system
  • Gasoline engines
  • Engine repair
  • Lubrication system
  • Cooling system
  • Control system
  • Power and exhaust system
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Drive shafts
  • Chassis
  • Car suspension
  • Steering
  • Tires and wheels
  • Brake system
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Doors and windows
  • Heating and ventilation
  • Electrical equipment
  • Equipment and devices
  • Power devices
  • Lighting and signaling
  • Electrical circuits
W124 (1984-1995) 
  • General information
  • Governing bodies
  • Driving and operation
  • Weekly care
  • Maintenance (gasoline)
  • Maintenance (diesel)
  • Troubleshooting
  • Power unit
  • I4 petrol engine
  • V6 petrol engine (SOHC)
  • V6 petrol engine (DOHC)
  • Diesel engines
  • Engine overhaul
  • Cooling system
  • Heating and ventilation
  • Fuel system (carburetor)
  • Injection system «Bosch CIS-E»
  • Injection system «Bosch HFM»
  • Diesel fuel system
  • Supply system
  • Starting and charging system
  • Ignition system (I4)
  • Ignition system (V6)
  • Preheating
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Drive shafts
  • Chassis
  • Brake system
  • Car suspension
  • Steering
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Doors, locks and windows
  • Electrical equipment
  • Equipment and devices
  • Switches
  • Headlights and lighting
  • Electrical circuits
W123 (1976-1985) 
  • General information
  • Introduction to the guide
  • Power unit
  • Engine device
  • Repair M102 engines
  • Repair M110 and M123 engines
  • Cooling and lubrication (M102)
  • Cooling (M110 and M123)
  • Ignition system
  • Power system «Stromberg»
  • Power system «Solex 4A1»
  • Fuel injection «K-Jetronic»
  • Fuel injection «L-Jetronic»
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Cardan and rear axle
  • Chassis
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Doors, locks and windows
  • Electrical equipment
  • Equipment and devices
  • Power devices
  • Electrical circuits
 
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