AR26.50-P-0420-15CW Assemble Main Shaft

AR26.50-P-0420-15CW Assemble Main Shaft
- TRANSMISSION 716.6 in MODEL 204, 212





716 589 02 33 00
Sleeve





716 589 01 33 00
Sleeve





711 589 07 15 00
Drift





000 589 52 37 00
Pliers





1 Lubricate friction ring (24) and mount idler gear of 2nd. gear (25).

The spur toothing of the idler gear of the 2nd. gear (25) and the cams (24a) of the friction ring (24) must face upwards.

2 Lubricate cone ring (23) and fit on friction ring (24).

The cams (23a) of the cone ring (23) must engage in the cutouts (25a) on the idler gear of the 2nd. gear (25).

3 Lubricate synchronizer ring (22) and install with conical surface on cone ring (23).

The long cams (22a) of the synchronizer ring (22) must engage in the notches between the cams (24a) of the friction ring (24).





Assemble synchronizer assembly

New synchronizer units of 1st./2nd. gear (51) are delivered in assembled condition.

4 Push sliding sleeve (17) onto 1st/2nd gear synchronizer body (18).

When pushing on the sliding sleeve (17), align it to ensure that the balls (21) will mesh with the center groove in the sliding sleeve teeth (arrow).

5 Insert slider (20), compression springs (19) and balls (21) between the synchronizer body of 1st./2nd. gear (18) and sliding sleeve (17).





6 Mount synchronizer unit of 1st./2nd. gear (51) onto idler gear of 2nd. gear (25).

Identification groove (arrow) of sliding sleeve (17) must face towards idler gear of 2nd. gear (25). If this is not the case, the 2nd gear may jump out during automotive operation.

The long cams (22a) of the synchronizer ring (22) must engage into the cutouts of the synchronizer body of the 1st./2nd. gear (18).





7 Place main shaft (27) in workshop press.

Output side must face upwards.

8 Slide needle bearing (26) onto main shaft (27) and lubricate.





9 Press preassembled unit of idler gear of 2nd. gear (25), friction ring (24), cone ring (23), synchronizer ring (22) and the synchronizer unit of 1st./2nd. gear (51) onto main shaft (27) using sleeve.

When pressing on, a counterforce must be applied at the 2nd gear idler gear (25) which prevents the parts falling apart. Do not change the alignment of the parts while pressing on otherwise the synchronizer ring (22), cone ring (23) and friction ring (24) will be damaged and new parts will have to be installed.

When pressing on a new synchronizer unit of the 1st./2nd. gear (51), cuttings may occur, which then have to be removed using compressed air.

10 Check for correct installation position: The idler gear of the 2nd. gear (25) must be able to be moved with minimum physical effort, as otherwise the friction ring (24), cone ring (23) and synchronizer ring (22) will have to be replaced!




11 Determine required thickness of the circlip (16):
- Insert test ring (thickness: 1.5 mm) into groove of main shaft (27) using pliers and press all the way down.
- Measure distance between test ring and top edge of groove in the main shaft (27) using feeler gauge.
- Calculate required thickness of new circlip (16) (measured value + test ring thickness 1.5 mm).
- Remove test ring using pliers.

12 Using pliers, insert a new circlip (16) of the determined thickness (steps: 0.05 mm).

Do not overstretch circlip (16). Pay attention to correct seating of circlip (16).





13 Lubricate cone ring (14) and fit in lubricated synchronizer ring (15).

The cams (14a) of the cone ring (14) must point up.

14 Lubricate friction ring (13) and fit in cone ring (14).

The long cams (15a) of the synchronizer ring (15) must be positioned between the cams (13a) of the friction ring (13).

15 Insert synchronizer ring (15) into 1st/2nd gear synchronizer unit (51).

The long cams (15a) of the synchronizer ring (15) must engage into the cutouts (arrow) of the synchronizer body of the 1st./2nd. gear (18).





16 Slide needle bearing (12) of idler gear of 1st gear (11) onto main shaft (27) and lubricate.
17 Slide idler gear of 1st gear (11) onto main shaft (27).

The cams (14a) of the cone ring (14) must engage in the cutouts (11a) on the idler gear of the 1st. gear (11).





18 Push thrust washer (10) onto main shaft (27).
19 Press sleeve (9) onto main shaft (27) using drift.





20 Push new sliding sleeve (6) onto synchronizer body at reverse gear idler gear (7).

The pointed tooth flanks must point upwards. The recesses (V) in the sliding sleeve gearing must be in the recesses of the synchronizer body.

21 Press clamping elements (5) into recesses of synchronizer body at reverse gear idler gear (7).

Balls of clamping elements (5) must point towards sliding sleeve (6).





22 Slide needle bearing (8) of reverse gear idler gear (7) on main shaft (27) and lubricate.
23 Lubricate synchronizer ring (4) and fit on synchronizer body of reverse gear idler gear (7).

The synchronizer ring's sliding sleeve (4) must engage in the recesses in the synchronizer body.

24 Push reverse gear idler gear (7) onto main shaft (27).





25 Lubricate cone of clutch body (3) and press clutch body (3) on to main shaft (27) with sleeve.

The cone must face the synchronizer ring (4).





Assemble synchronizer assembly

New synchronizer units of 5th./6th. gear (52) are delivered in assembled condition.

26 Push sliding sleeve (36) onto 5th/6th gear synchronizer body (32).

When pushing on the sliding sleeve (36), align it to ensure that the balls (35) will mesh with the center groove in the sliding sleeve teeth (arrow).

27 Insert slider (34), compression springs (33) and balls (35) between the synchronizer body of 5th./6th. gear (32) and sliding sleeve (36).





28 Insert clutch body (30) into toothing of idler gear of 6th. gear (29) and lubricate.
29 Lubricate synchronizer ring (31) and fit on clutch body (30).
30 Place synchronizer unit of 5th./6th. gear (52) onto synchronizer ring (31).

The side with the embossed part number must face upwards. The synchronizer ring's sliding sleeve (31) must engage in the recesses in the synchronizer body (32).





31 Place main shaft (27) in workshop press.

Drive side must face upwards.

32 Slide needle bearing (28) of idler gear of 6th gear (29) onto main shaft (27) and lubricate.
33 Press preassembled unit of 6th gear idler gear (29), clutch body (30), synchronizer ring (31) and 5th/6th gear synchronizer unit (52) onto main shaft (27) using sleeve.

When pressing on, a counterforce must be applied at the 6th gear idler gear (29) which prevents the parts falling apart. Do not change the alignment of the parts while pressing on otherwise the synchronizer ring (31) will be damaged and a new part will have to be installed.

When pressing on a new synchronizer unit of the 5th./6th. gear (52), cuttings may occur, which then have to be removed using compressed air.

34 Check correct installation position: Idler gear of 6th. gear (29) must be movable with minimum physical effort, otherwise the synchronizer ring (31) will have to be replaced.





35 Determine required thickness of the circlip (39):
- Insert test ring (thickness: 1.5 mm) into groove of main shaft (27) using pliers and press all the way down.
- Measure distance between test ring and top edge of groove in the main shaft (27) using feeler gauge.
- Calculate required thickness of new circlip (39) (measured value + test ring thickness 1.5 mm).
- Remove test ring using pliers.

36 Using pliers, insert a new circlip (39) of the determined thickness (steps: 0.05 mm).

Do not overstretch circlip (39). Ensure circlip (39) is seated correctly.





37 Lubricate synchronizer ring (37) and insert into synchronizer unit of 5th./6th. gear (52).

The drivers of the synchronizer ring (37) must engage in the cutouts of the synchronizer unit of 5th/6th gear (52).
38 Push cylindrical roller bearing (40) onto main shaft (27) and lubricate.
39 Lubricate clutch body (38) and fit in gearing of drive shaft (41).
40 Push drive shaft (41) with clutch body (38) onto main shaft (27).
41 Remove main shaft (27) with drive shaft (41) from workshop press.