Dissassembly, Assembly and Measurement of Gear Set

DISMANTLING, ASSEMBLING AND MEASURING GEAR SET





Lubricating thrust ring (99)
Remove, when installing, insert with grease (item 1).
Gear Set, complete
Clamp in assembly bracket 126 589 00 35 00 with output shaft (item 2).
Snap ring (3)
Remove, install using screwdriver (item 3).
Front planetary gear set (2)
Take off together with axial bearing (23) (items 4 and 5).
Axial bearing (4) and drive shaft (1)
Remove (item 6).
Output shaft (8)
Remove together with radial bearing (5) and axial bearing (6) (items 7 and 8).
Axial bearing (9) and sun gear (10)
Remove, install (item 9).
Snap ring (21)
Remove, install using screwdriver (item 10).
Inside disc carrier K2 (19) with free-wheeling unit
Remove from and insert into connector (7) complete. After assembly, adjust axial play between free-wheeling unit and connector to 0.05 - 0.2 mm (Items 19 - 22).
Support disc (11)
Lift Off. When fitting, the lugs must engage in the bore in the outside ring of the free-wheeling unit (item 12).
Shim ring (1/) and O-ring (12)
Remove, install (item 13).
Inside ring of free-wheeling unit (13)
Remove and install in counter-clockwise direction. Refer to item 14 for installation note.
Cylinder rollers (16) arid roller cage (14) with compression O-rings (15)
Remove, install, check (items 15 - 16).
Outside ring of free-wheeling unit (24)
Remove, install, check (item 17).
Friction ring (18) and O-ring (20)
Check (item 18).

Special Tool:

Auxiliary tool (spare part)
Retaining plates (16 plates) - 126 277 00 73

NOTE: Lubricate bearings and sliding surfaces when assembling.

Dismantling and assembling

1. Remove lubricating thrust ring (99) from drive shaft.

Installation Note
Insert lubricating thrust ring into groove with grease in such a way that the diagonal cut remains closed.

2. Clamp assembly bracket 126 589 00 35 00 into vice by the two flat surfaces and with the plate uppermost. Position gear set in assembly bracket output shaft first.





3. Remove snap ring (3).

Installation Note
After inserting, push snap ring into groove using a screwdriver after the front gear set has been fitted.





4. Lift off front planetary gear set (2).
5. Remove axial bearing (23) from planetary gear set and check.





6. Take off axial bearing (A) and drive shaft (1).





7. Remove radial bearing (5) and axial bearing (6).
8. Take out output shaft (8).





9. Remove axial bearing (9) and pull out sun gear (10).

Installation Note
Insert sun gear (10) into free-wheeling unit and rotate; the free-wheeling unit must lock in the direction of the arrow. Then place axial bearing (9) onto sun gear.





10. Turn connector and take out snap ring (21).

Installation Note
Press snap ring into groove using a screwdriver.

11. Lift inside disc carrier K2 (19) with free-wheeling unit out of connector (7).





12. Lift off support disc (11).

Installation Note
Position support disc (11) so that the lug engages in the bore in the outside ring of the free-wheeling unit (arrows).

13. Remove shim ring (17) and O-ring (12).





14. Turn inside ring of free-wheeling unit (13) in direction of arrow and pull out.

Installation Note





15. Press cylinder rollers (16) against compression springs (15) and insert retaining plates (085) with the rounded edge pointing outwards. The retaining plates can be acquired as auxiliary tools via part no. 126 277 00 73 (16 plates). Insert inside ring of free-wheeling unit (13) while rotating in a counter-clockwise direction, then remove retaining plates (085).





16. Remove cylinder rollers (16) and roller cage (14) with compression springs (15), check parts for damage.
17. Remove outside ring of free-wheeling unit (24).





18. Check thrust washer (18) and O-ring (20) for damage and wear.

Measuring





19. Check axial play of free-wheeling unit and correct. Check clearance between free-wheeling unit and connector (7) using a feeler gage.

NOTE: The 0-rings (12, 20) must not be installed during the measurement.





20. Correct clearance to 0.05 - 0.2 mm using shims (22); then insert 0-rings (12 and 20) (figure to items 12, 16).
21. Place shims (22) in connector (7).
22. Hold free-wheeling unit together and insert circlip into connector.