AR26.50-D-4775-03D Assemble Countershaft

AR26.50-D-4775-03D Assemble Countershaft
- TRANSMISSION 711.651





711 589 01 37 00
Set of assembly clamps





711 589 17 15 00
Drift

For installing the synchronizer unit of 3rd/4th gear, the fixed gear of 6th gear and constant speed gear the respective seat on the countershaft and contact surfaces of the components must be grease-free.

A workshop press is required for pressing on. The required press force for the gear wheels is approx. 15 t and that for the synchronizer unit is approx. 3 t.

Oil clutch bodies, friction rings, cone rings, synchronizer rings and needle bearings lightly with automatic transmission fluid before installing.





1 Install clutch body (15) on idler gear of 4th gear (16).





Do not mix up the clutch bodies (6, 15) of the synchronizer unit of 3rd/4th gear. The clutch bodies are distinguished in the direction of the tooth pointing (arrows). The clutch body (6) is installed on the idler gear of 3rd gear.





2 Install friction ring (14) and cone ring (13).

The cams of the friction ring (14) must point towards the drive side. The cams of the cone ring (13) must engage in the cutouts of the clutch body (15).

3 Install synchronizer ring (12).

The toothing of the synchronizer ring (12) must point towards the idler gear of 4th gear (16). The cams of the friction ring (14) must engage in the cutouts of the synchronizer ring (12).

4 Attach synchronizer unit of 3rd/4th gear (11).

The marking groove on the collar of the sliding sleeve for synchronizer unit of 3rd/4th gear (11) must point towards the drive side. The cams of the synchronizer ring (14) must engage in the cutouts of the synchronizer unit of 3rd/4th gear (11).





5 Attach countershaft with output side on the workshop press mount.
6 Install needle bearing of 4th gear (17).
7 Secure synchronizer unit of 3rd/4th gear (11) and idler gear of 4th gear (16) with assembly clamp (21) and press on as far as the end stop using drift.
8 Remove assembly clamp (21).





9 Determine thickness of the circlip (10):

- Insert circlip (10) with a thickness of 2 mm as test ring in the security groove and press downwards until it abuts in the direction of the synchronizer unit of 3rd/4th gear (11).
- Measure the gap between the test ring and the upper edge of the security groove using a feeler gauge.
- Thickness of required circlip (10) = measured value + 2 mm (test ring).
- Remove test ring.

Circlips (10) are available with a thickness of 2.00 up to 2.35 mm and a graduation of 0.05 mm.

10 Install circlip (10).





11 Install synchronizer ring (9) and cone ring (8).

The cams of the synchronizer ring (9) must engage in the cutouts of the synchronizer unit of 3rd/4th gear (11). The cams of the cone ring (8) must point towards the drive side.

12 Attach friction ring (7) and clutch body (6).

The lobes on the friction ring (7) must engage with the cutouts of the synchronizer ring (9). The cams of the cone ring (8) must engage in the cutouts of the clutch body (6).

13 Install needle bearing of 3rd gear (5) and idler gear of 3rd gear (4).





14 Press on fixed gear of 6th gear (3) as far as the end stop using drift.

The collar of the fixed gear of 6th gear (3) must point towards the drive side.

15 Press on constant speed gear (2) as far as the end stop using drift.

The collar of the constant speed gear (2) must point towards the fixed gear of 6th gear (3). After pressing on it must still be possible to turn the idler gears of 3rd gear and 4th gear freely.

16 Install new circlip (1).