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

AR26.50-D-4775-03E Assemble countershaft
- Transmission 711.670

Special Tools:

For installing the synchronizer unit of 3rd/4th gear, then 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.

Component Identification:

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

Component Identification:

Do not mix up the clutch bodies (7, 15) of the synchronizer unit of 3rd/4th gear. The clutch bodies (7, 15) differ in the alignment of the tips of the teeth (arrows). The clutch body (7) is installed on the idler gear of 3rd gear.

Component Identification:

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 sliding sleeve collar of the 3rd/4th gear synchronizer unit (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).

Component Identification:

5 Attach countershaft with output side on the workshop press mount.
6 Slide the 4th gear needle bearing (17) onto the countershaft.
7 Secure synchronizer unit of 3rd/4th gear (11) and idler gear of 4th near (16) with assembly clamp (21) and press on as far as the end stop using l2jr drift.
8 Remove assembly clamp (21).

Component Identification:

9 Install synchronizer ring (10) and cone ring (9).

The cams of the synchronizer ring (10) must engage in the cutouts of the synchronizer unit of 3rd/4th gear (11). The cams of the cone ring (9) must point towards the drive side.
10 Mount friction ring (8) and clutch body (7).
The lobes on the friction ring (8) must engage with the cutouts of the synchronizer ring (10). The cams of the cone ring (9) must engage in the cutouts of the clutch body (7).

Component Identification:

11 Press on thrust plate (6) and bearing bushing of 3rd gear (5) as far as the end stop using drift.
The thrust plate (6) must abut with the wide contact surface on the synchronizer unit of 3rd/4th gear (11).
12 Mount needle bearing of 3rd gear (4) and idler gear of 3rd gear (3).
The straight toothing of the idler gear of 3rd gear (3) must engage in the clutch body (7).

Component Identification:

13 Press on fixed gear of 6th gear (2) as far as the end stop using drift.
The collar of the fixed gear of 6th gear (2) must point towards the drive side.

After pressing on, the 3rd and 4th gear idler gears must turn freely.
14 Press on constant speed gear (1) as far as the end stop using drift.
The collar of the constant speed gear (1) must point towards the fixed gear of 6th gear (2).
15 Remove countershaft (18) from the workshop press mount.

Component Identification:

16 Clip on the roller bearing intermediate plate (19).
17 Screw oil guide ring (20) onto the toothing.
The installation position of the oil guide ring (20) must be adjusted when moving together the countershaft (18) and main shaft.