Taking the input shaft out of a 4 speed manual transmission

[GGR]

Hi all,
I'm trying to get the input shaft of a G76/27 four speed manual transmission out. So far I was able to take the front cover out as well as the top bearing on the input shaft. But the input shaft won't come out because a gear on the lower shaft is blocking it.

I was thinking to take the front bearing of the lower shaft out so that I can have some play and get the output shaft out. Unfortunately I am unable to take the nut on the lower shaft out. Is it unbolting clockwise like on the top shaft or ccw as normal?

I guess I could hold the lower shaft from the other side but I can't take the nut of the output flange out as I don't have the special slotted wrench. I can immobilize the output flange but I fear to damage pinions inside as that bolt is very hard to undo.

Any helpful idea would be greatly appreciated!

[bwostosh]

I ran into the same problem. I just wanted the shaft for a clutch installation tool. Now I just use the whole trans minus the bell housing to align clutch.
I should just saw it off.
By the way spare transmissions used to be $60 at pick a part.
I cant imagine rebuilding one. $$$$ +

[Tony H]

It's not as expensive as you might think. I had my stick shift 3.5 tranny rebuilt by Mercedes Werkstatt-a very high quality shop. $1400. But they had it for a year. Good thing I was not in a hurry.

[sjefke]

I have a copy of "service manual for 4 speed manual MB transmissions starting 1977" and as far as I can see/read, you need to remove both front AND rear ball bearings first. That will/should give you the clearance to raise the shaft high and pull it out. It says that "manual four speed transmissions G76/18, G76/27, 716.0 as well as 716.1, are essentially the same" (from an assembly point of view).

Good luck,

Bert

[sjefke]

Attached is picture of relevant service manual page.

Bert

[GGR]

Thank you, this is what i thought. I unfortunately do not have the necessary special socket to get the sloted output flange out and it is too far inside the flange to untighten it with a screwdriver and a hammer. Would someone know where I can get such a special socket? A copy of that "service manual for 4 speed manual MB transmissions starting 1977" would be quite useful to me. Where can I get one? Alternatively, sjefke, if it"s not too bulky, can it be scanned?

Thanks in advance!

[Chas H]

Originally Posted by GGR

Thank you, this is what i thought. I unfortunately do not have the necessary special socket to get the sloted output flange out and it is too far inside the flange to untighten it with a screwdriver and a hammer. Would someone know where I can get such a special socket? A copy of that "service manual for 4 speed manual MB transmissions starting 1977" would be quite useful to me. Where can I get one? Alternatively, sjefke, if it"s not too bulky, can it be scanned?

Thanks in advance!

I've had (1) of these trans apart and the bearings easily came off their shafts using pry bars.

[sjefke]

I have it in electronic form but it is 100mb. I pulled it from an online source and I cannot remember where it was. I thought some W116 site had it, but I cannot find the site anymore. Anyway, I can e-mail it to you, but you'd better have a big inbox . Alternatively, I can burn it on a CD and snail mail it. Or do you have some ftp site I can dump it on? It is a pdf, but somebody scanned every page of the manual in bitmap picture format, which makes it big. I wish they had scanned it directly to pdf.

Perhaps one of the forum members knows/remembers the site I am talking about so you can download it directly to your computer.

I'll try to do some computer wizardry to see whether I can get the size smaller.

Bert

[GGR]

Thanks! Let's see if someone comes out with a link. Otherwise I would definitely be interested in a CD.

[sjefke]

Send me a pm. I just did some acrobat professional stuff with it and got it down to 31 MB. That is in e-mail range. Plus it is searchable now

Bert