AR26.50-P-4775-03CW Assemble Countershaft

AR26.50-P-4775-03CW Assemble countershaft
- TRANSMISSION 716.6

Special Tools:

Component Identification:

On vehicles equipped with a gasoline engine, with the exception of gearwheels for 1st. gear and reverse gear, other gearwheels are installed than those in vehicles with a diesel engine. To tell the gearwheels apart, the gearwheels for vehicles with a diesel engine come with an identification groove (arrow) in the toothing.

Component Identification:

1 Clamp the countershaft in a vise with jaw protectors.
Drive side must face upwards.
2 Install 4th gear needle bearing (22).
3 Install 4th gear wheel (21).
The spur toothing must point upwards.
4 Mount clutch body of 4th. gear (20), with outer toothing facing downwards (towards output), onto countershaft.
Risk of confusion! The clutch bodies (6, 20) for the 3rd and 4th gears differ in the direction of the tooth tips (arrows):
^ Clutch body of 4th. gear (20):
Long side of tip faces left.
^ Clutch body of 3rd. gear (6):
Long side of tip faces right.

Component Identification:

5 Install the friction ring (19).
The cams must face upwards (towards drive end).
6 Install synchronizer cone ring (18).
The lobes must engage in the recesses (arrow) in the clutch body.
7 Install synchronizer ring (17).
Toothing must point downwards (towards output end).
The cams of the friction ring (19) must engage in the recesses in the synchronizer ring (17).

Component Identification:

Assemble new synchronizer assembly:
8 Insert greased blocking pieces (10) into sliding sleeve (11).
The grooves on the blocking pieces(10) must face inward.
9 Push sliding sleeve (11) onto 3rd/4th gear synchronizer body (16).
When pushing on the sliding sleeve (11), align it to ensure that the balls (15) will mesh with the center groove in the sliding sleeve teeth (arrow).
10 Install wide sliders (14), thrust springs (13) and balls (15) into 3rd/4th gear synchronizer body (16).
The sliders (14) for the individual synchronizer bodies have different widths:
^ Synchronizer body of 1st./2nd. gear: Width slider (15 mm)
^ Synchronizer body of 3rd./4th. gear: Width slider (15 mm)
^ Synchronizer body of 5th/6th. gear: Narrow slider (9 mm)
^ Reverse gear synchronizer body: narrow sliders (9 mm)

Component Identification:

11 Install new 3rd/4th gear synchronizer unit (30) and press on using sleeve.
The identification groove on the sliding sleeve must face upwards.
The 3 long lobes (arrow) of the synchronizer ring must engage in the recesses of the synchronizer body.
Shavings can be produced when the new synchronizer body is pressed on. These must be removed with compressed air.
Blow out countershaft.

Component Identification:

12 Determine required thickness of the circlip (12):
^ Insert test ring (thickness: 1.5 mm) using suitable pliers and push all the way down (towards drive).
^ Calculate required thickness of new circlip (12) (measured value + test ring thickness 1.5 mm).
^ Remove test ring using suitable pliers.
13 Using suitable pliers, insert a new circlip (12) of the determined thickness (steps: 0.05 mm).
Do not overstretch circlip (12). Pay attention to correct seating of circlip (12).
14 Install synchronizer ring (9).
Toothing must face upwards (towards drive end). The 3 long lobes in the synchronizer ring (9) must engage with the recesses in the synchronizer body.
15 Install synchronizer cone ring (8).
The cams must face upwards (towards drive end).

Component Identification:

16 Install the friction ring (7).
The lobes must engage in the cutouts in the synchronizer ring.
17 Install clutch body (6).
The lobes in the synchronizer ring must engage in the cutouts in the clutch body (6).
18 Install 3rd gear needle bearing (5).
19 Install 3rd gear wheel (4).
The straight teeth must point downwards (towards the output end).

Component Identification:

20 Heat 6th gear fixed gear (3) to approx. 120 degrees C and press on with sleeve.
Collar must face upwards (towards drive end). During the pressing operation hold the 3rd gear wheel in place to prevent the 3rd gear clutch body from jumping out of the synchronizer ring cam.
21 Heat constant-mesh gear (2) to approx. 120 degrees C and press on with sleeve.
Collar must face downwards (towards output end).
22 Install new circlip (1).
23 Release the countershaft from vise.