Removal and installation the intermediate crankcase (Mercedes-Benz S-Class W140)

Removal

1. Remove the retaining ring (45). Remove the reverse gear (48) with the needle bearing and two gaskets (44) from the reverse shaft (46).



2. Remove the reverse gear helical gear (52) with the hub (51) using a puller and remove the needle bearing (55).





3. Remove the lever (64), fork (63) and clutch (62) for engaging 1st gear from the driven shaft.



4. Remove the 1st/reverse gear synchronizer (58) together with the reverse gear sleeve (57).



5. Remove the 1st gear helical gear (59) with the synchronizer ring (63) and needle bearing (60) from the driven shaft.





6. Using two screwdrivers, remove the friction ring (65) and bushing (61) so that the friction ring (65) protrudes by approximately 3 mm. If the bushing is pressed in tightly, it must be heated slightly.



7. Remove the friction ring and bushing using a puller.



8. Unscrew the bolts (69) securing the holder.





9. Remove the intermediate case (49) from the gearbox.



10. Using a puller, remove the 2nd gear helical gear (33) and ball bearing (70) with holder (73).



11. Remove the 2nd gear helical gear (33) and linings (36) from the driven shaft.

Installation

1. Press the ball bearing (70) into the intermediate plate and secure with the holder (73). Tighten the bolts (69) to 30 Nm.



2. Replace the gasket.

3. Using a press, press the intermediate plate onto the driven shaft and gearbox housing.



4. Install the linings (66) onto the friction ring (65).



5. Install the synchronizer (58) with the flange towards the 1st gear bevel gear (59). Heat the sleeve to approximately 80°C.



Original published on the website [MercedesMAN]



6. Insert the fork into the lever so that the short arm (arrow) is positioned towards the reverse clutch.



Further installation is carried out in the reverse order of removal.