Disassemble and assemble main shaft

AR26.50-I-0420B

Disassemble and assemble main shaft

24.4.07

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A



Removing

1

Remove rear section of transmission housing

AR26.40-I-2475B



Disassemble

2

Clamp output side of main shaft (1) in vise.

 Use suitable aluminum protective jaws.

3

Remove the synchronizer cone for the toothed gear of the 4th. gear (2)

 The synchronizer cone and synchronizer body must not be interchanged. Note assignment and installation position.

4

Detach front, output-end tapered roller bearing
(3).

AR26.50-I-0440-01A



*710589046300

5

Remove 3rd/4th gear sliding sleeve (4)

 When doing so wrap a rag around the sliding sleeve for the 3rd./4th. gear (4), to prevent the push springs (30), balls (31) and pressure parts (32) from falling down.

6

Remove circlip (5)

7

Remove the synchronizer body for 3rd./4th. gear (6)

AR26.50-I-0420-26A



*710589036300

8

Remove the synchronizer cone for the toothed gear of the 3rd. gear (7)

 The synchronizer cone and synchronizer body must not be interchanged. Note assignment and installation position.

9

Remove toothed gear of 3rd. gear (8) from main shaft (1)

10

Remove needle cage for toothed gear of 3rd. gear (9) from main shaft (1)

11

Remove toothed gear for 2nd. gear with synchronizer ring (11)

AR26.50-I-0420-09A



*710589036300

12

Remove needle cage for toothed gear of 2nd. gear (15) from main shaft (1)

13

Remove circlip (16)

14

Use suitable puller to detach toothed gear of 1st. gear (26) and remove together with the synchronizer cone for the 2nd gear toothed gear (14), the synchronizer body of the 1st./2nd. gear (27) and the synchronizer cone for the 1st. gear toothed gear (28)

15

Remove needle cage for toothed gear of 1st. gear (29) from main shaft (1)

16

Clamp input side of main shaft (1) in vise.

 Use suitable aluminum protective jaws.

17

Detach rear, drive-end
tapered roller bearing (17)

AR26.50-I-0440-01A



*710589046300



*001589413300

18

Remove toothed gear of 5th. gear with synchronizer ring (18) from main shaft (1)

19

Remove needle cage for toothed gear of 5th. gear (19) from main shaft (1)

20

Remove the synchronizer cone for the toothed gear of the 5th. gear (20)

 The synchronizer cone and synchronizer body must not be interchanged. Note assignment and installation position.

21

Remove circlip (21)

22

Remove sliding sleeve of 5th./reverse gear (22)

 When doing so wrap a rag around the sliding sleeve for the 5th/reverse gear (22), to prevent the push springs (30), balls (31) and pressure parts (32) from falling down.

23

Remove the synchronizer body
of the 5th./reverse gear (23)

AR26.50-I-0420-26A



*710589036300

24

Detach reverse gear gearwheel (24) from main shaft (1).

25

Detach reverse gear gearwheel needle cage (25) from main shaft (1).



Checking

26

Check wear limit of synchronizer rings

AR26.50-I-0420-17B

*BE26.50-N-1001-04B



Metal strip for checking play between synchronizer ring and synchronizer cone.

WF58.50-N-2650-04A



Assemble

27

Push reverse gear gearwheel needle cage (25) onto main shaft (1).

 Use transmission oil to lubricate the reverse gear toothed gear
needle cage (25).



Synthetic gear oils (SAE 75 W/85 W)

Sheet 235.4

BB00.40-P-0235-04A

28

Push reverse gear gearwheel (24) onto main shaft (1).

 The gearing at the synchronizer ring must face the output side.

29

Heat the synchronizer body of the
5th./reverse gear (23) to approx. 130 to
150 °C for a maximum of 15 min, and then use a suitable drift to press it on to the end stop on the main shaft (1)

 The ring welded on to the synchronizer body
of the 5th./reverse gear (23) must face towards the toothed gear
for the reverse gear (24).

30

Install circlip (21).

31

Check axial play of circlip (21) and toothed gear for reverse gear (24)

 If necessary, fit circlip (21) of appropriate thickness.

*BE26.50-N-1002-04B

*BE26.50-N-1003-04B

32

Insert push springs (30), pressure parts (32) and balls (31) into the bores in the synchronizer body of the 5th./reverse gear (23) and mount the sliding sleeve of the 5th./reverse gear (22)

 The lettering "1307 304 544 FRONT" of the sliding sleeve of the 5th./reverse gear (22) must face towards the drive side.

33

Insert the synchronizer cone for the toothed gear of the 5th.gear (20) into the synchronizer body of the 5th./
reverse gear (23)

34

Mount needle cage for toothed gear of 5th. gear (19) onto main shaft (1).

 Use transmission oil to lubricate needle cage for toothed gear on 5th. gear (19).



Synthetic gear oils (SAE 75 W/85 W)

Sheet 235.4

BB00.40-P-0235-04A

35

Mount toothed gear of 5th. gear with synchronizer ring (18) onto the main shaft (1)

36

Heat inner bearing race of rear, drive-end tapered roller bearing (17) to approx. 130 to 150 °C for a maximum of 15 min, and then, using a suitable drift, push on to the end stop on the main shaft (1)

37

Check axial play of toothed gear of 5th. gear with synchronizer ring (18)

*BE26.50-N-1007-04B

38

Clamp output side of main shaft (1) in vise.

 Use suitable aluminum protective jaws.

39

Mount needle cage for toothed gear of 1st. gear (29) onto main shaft (1).

 Use transmission oil to lubricate needle cage for toothed gear on 1st. gear (29).



Synthetic gear oils (SAE 75 W/85 W)

Sheet 235.4

BB00.40-P-0235-04A

40

Slide toothed gear of 1st. gear (26) onto needle cage for toothed gear of 1st. gear (29)

41

Insert the synchronizer cone for the toothed gear of the 1st. gear (28)

42

Heat the synchronizer body of the 1st./2nd. gear (27) up to approx. 130 to 150 °C for a maximum of 15 min and then use a suitable drift to press it onto the end stop on the main shaft (1)

 The side of the synchronizer body
of the 1st./2nd. gear (27) with the "ENGINE SIDE" marking must face towards the drive.

43

Check the synchronizer cone for the toothed gear of the 1st. gear (28) runs smoothly by moving it up and down

44

Install circlip (16).

45

Check axial play of circlip (16) and toothed gear of 1st. gear (26)

 If necessary, fit circlip (16) of appropriate thickness.

*BE26.50-N-1002-04B

*BE26.50-N-1004-04B

46

Insert push springs (30), pressure parts (32) and balls (31) into the bores in the synchronizer body of the 1st./2nd. gear (27), and mount the sliding sleeve of the 1st./2nd. gear (10)

 The chamfering side of the sliding sleeve of the 1st./2nd. gear (10) must face towards the drive end.

47

Insert the synchronizer cone for the toothed gear of the 2nd. gear (14) into the sliding sleeve of the 1st./2nd. gear (10)

48

Fit toothed gear of 2nd. gear with synchronizer ring (11)

AR26.50-I-0420-09A



Synthetic gear oils (SAE 75 W/85 W)

Sheet 235.4

BB00.40-P-0235-04A



*710589036300

49

Check the synchronizer cone for the toothed gear of the 2nd. gear (14) runs smoothly by moving it up and down

50

Heat thrust plate (12) and bearing bushing of needle cage for toothed gear of 3rd. gear (13) to approx. 130 to 150 °C for a maximum 15 min, and then use a suitable drift to press it onto the end stop on the main shaft (1)

51

Check axial play of toothed gear of 2nd. gear with synchronizer ring (11)

*BE26.50-N-1005-04B

52

Slide needle cage for toothed gear of 3rd. gear (9) on bearing bushing of needle cage for toothed gear

of 3rd. gear (13) onto main shaft (1)

 Use transmission oil to lubricate needle cage for toothed gear on 3rd. gear (9).



Synthetic gear oils (SAE 75 W/85 W)

Sheet 235.4

BB00.40-P-0235-04A

53

Slide toothed gear of 3rd. gear (8) onto needle cage for toothed gear of 3rd. gear (9)

 The synchronizer ring of the toothed gear
of the 3rd. gear (8) must face towards the drive side.

54

Mount the synchronizer cone for the toothed gear of the 3rd. gear (7) onto the toothed gear of the 3rd. gear (8)

55

Heat the synchronizer body for 3rd./4th. gear (6) to

approx. 130 °C to 150 °C for a maximum of 15 minutes and then use a suitable drift to press it up to the end stop on the main shaft (1).

56

Check the synchronizer cone for the toothed gear of the 3rd. gear (7) runs smoothly by moving it up and down

57

Check axial play of toothed gear of 3rd. gear (8)

*BE26.50-N-1006-04B

58

Install circlip (5)

 If necessary, select circlip (5) of appropriate thickness. Aim for a setting without play.

*BE26.50-N-1002-04B

59

Insert push springs (30), pressure parts (32) and balls (31) into the bores in the synchronizer body of the 3rd./4th. gear (6), and mount the sliding sleeve of the 3rd./4th. gear (4)

 The lettering "1307 304 371 FRONT" of the sliding sleeve of 3rd./4th. gear (4) must face towards the drive side.

60

Insert the synchronizer cone for the toothed gear of the 4th. gear (2) into the synchronizer body of the 3rd./4th. gear (6)

61

Heat inner bearing race of front, output-end tapered roller bearing (3) to approx. 130 to 150 °C for a maximum of 15 min, and then, using a suitable drift, push on to the end stop on the main shaft (1)



Install

62

Install rear section of transmission housing

AR26.40-I-2475B

Number

Designation

Trans-mission 712.353

BE26.50-N-1001-04B

Play between synchronizer cone and synchronizer ring

mm

0,6

BE26.50-N-1002-04B

Play of locking ring in annular groove on main shaft

mm

0.00 to 0.05

BE26.50-N-1003-04B

Axial play of reverse gear gearwheel

mm

0.15 to 0.30

BE26.50-N-1004-04B

Axial play for toothed gear of 1st. gear

mm

0.15 to 0.30

BE26.50-N-1005-04B

Axial play for toothed gear of 2nd. gear

mm

0.15 to 0.40

BE26.50-N-1006-04B

Axial play for toothed gear of 3rd. gear

mm

0.15 to 0.30

BE26.50-N-1007-04B

Axial play for toothed gear of 5th. gear

mm

0.15 to 0.30