26 - 6475 Shifter assembly - Dismantling and assembly
Vehicle Model 601., 602., 611. (up to Vehicle Ident. End No. 941 505)
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1 Shift assembly casing 16 Spring washer
2 Lock 17 1st/reverse gear lever check
3 Spring check 18 2nd/3rd gear lever check
4 PIn 19 4th/5th gear lever check
5 Reverse gear switch check 20 Washer
6 Bolt 21 Plastic bushing check
7 Reverse gear travel stop 22 Circlip
8 Plastic cover 23 Shift tube check
9 Circlip 24 PIn
10 Seal cap 25 Plastic guide check
11 Circlip 26 Shift lever
12 Plastic bushing check 27 Spring check
13 Circlip 28 Curved plate
14 Spring check 29 Cover
15 Washer 30 Dust cap
Shop-made tool
Drift punch Z26-455
Dismantling
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1 Remove plastic cover and dust cap.
2 Remove shift lever.
3 Remove reverse gear travel stop.
4 Release circlip and remove seal cap.
5 Remove reversing lamp switch.
6 Remove pin, spring and lock.
7 Remove circlips holding springs.
8 Remove circlip.
9 Pull out shift tube. Remove spring, lever with washers and spring washer.
10 Remove circlip and plastic bushing.
11 Inspect all components, noting both general condition and any particular signs of wear.
Assembly
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1 Install plastic sleeve and circlip.
2 Insert spring.
3 Guide in assembly punch. Install washers with spring washer and lever.
4 Bring shift tube into position and sldie it through.
5 Install plastic bushing and circlip.
6 Compress the spring and install the circlip.
7 Install lock, spring, pin and reversing lamp switch.
8 Install seal cap and circlip.
9 Install reverse gear travel stop.
10 Install shift lever.
11 Install plastic cover and dust cap.
26 - 6475 Shifter assembly - Dismantling and assembly
Left-hand drive, Model 601., 602., 611 (from Vehicle Ident. End No. 941 506)
1 Shift shaft check, replace as necessary 2 PIn check, replace as necessary 3 PIn check, replace as necessary 4 PIn check, replace as necessary 5 Cover 6 Circlip check, replace as necessary 7 Bushing check, replace as necessary 8 Base assembly housing check, replace as necessary 9 Bushing check, replace as necessary 10 Spring check, replace as necessary 11 Bearing check, replace as necessary 12 PIn 13 PIn 14 Bearing check, replace as necessary 15 Circlip check, replace as necessary 16 Shift lever grease 17 Dust cap 18 Washer 19 Spring washer check, replace as necessary 20 Spring ring check, replace as necessary 21 Cover 22 Circlip check, replace as necessary 23 Circlip check, replace as necessary | 24 Bushing check, replace as necessary 25 Washer 26 Spring check, replace as necessary 27 Circlip check, replace as necessary 28 Shim ring 29 Spring check, replace as necessary 30 Washer 31 Nut 32 Reverse gear switch check, replace as necessary 33 Spring washer 34 Bolt 35 Shim 36 Spring washer check, replace as necessary 37 Spring washer check, replace as necessary 38 Shim 39 4th/5th gear lever check, replace as necessary 40 2nd/3rd gear lever check, replace as necessary 41 1st/reverse gear lever check, replace as necessary 42 Spacer sleeve check, replace as necessary 43 Shift gate check, replace as necessary 44 Washer check, replace as necessary 45 Shift gate check, replace as necessary |
Dismantling
1 Remove cover (5) and dust cap (17).
2 Remove circlip (15) and take off upper bearing half (14).
3 Remove shift lever (16).
4 Press out pins (12, 13)
Note
Press lower bearing half (11) down, under tension.
5 Remove lower bearing half (11) with spring (10).
6 Extract circlip (22) and remove cover (21).
7 Remove spring ring (20), spring washer (19) and washer (18).
8 Remove circlip (23) from base assembly housing (8), then remove plastic bushing (24) together with washer (25) and spring (26).
Note
Plastic bushing is under tension.
9 Remove circlip (27) from the shift shaft. remove shim ring (28) with spring (29) and washer (30).
Note
Shim ring is under spring tension.
10 Remove reversing lamp switch (32).
11 Remove circlip (6).
12 Pull out shift shaft (1) along with plastic bushing (7), washers (35, 38) and spring washers (36,37).
13 Remove the levers (39, 40, 41) from the base assembly housing.
14 Remove spacer sleeve (42) with shift gates (43, 45) and washer (44).
Note
Note installation position of the shift gates
(43, 45).
15 Press the pins (2, 3 4) from the shift shaft (1). Remove washers (35, 38), spring washers (36, 37), plastic bushing (7) and circlip (6).
16 Inspect all components, noting both general condition and any particular signs of wear; install new parts as necessary.
Assembly
1 Slide circlip (6), plastic bushing (7), spring washers (36, 37) and washers (35, 38) onto the shift shaft (1), then install the pins (2, 3, 4).
Note
Note that the diameters of the pins are not identical.
2 Install spacer sleeve (42) with shift gates (43, 45) and washger (44) in the base assembly housing.
Note
Ensure that the shift gates (43, 45) are installed in the correct positions.
3 Install the levers (39, 40, 41) in the base assembly housing.
4 Place shift shaft (1) in position and slide it through, install circlip (6).
5 Install reversing lamp switch (32).
6 Slide washer (30), spring (29) and shim ring (28) onto the shift shaft.
7 Push back the shim ring and install the circlip (27) in the shift shaft.
8 Install spring (26), washer (25) and plastic bushing (24).
9 Press back the plastic bushing and install circlip (23).
10 Install washer (18), spring washer (19) and spring ring (20).
Note
Install the spring washer with the convex side toward the inside.
11 Install cover (21) and circlip (22).
12 Install spring (10) and lower bearing half (11).
13 Push down lower bearing half (11) and install both pins (12, 13).
Note
Ensure that Dimension "a" = 21 +- 0.5 mm is correct.
14 Install shift lever (16).
15 Install upper bearing half (14) with circlip (15).
16 Install cover (5) and dust cap (17).
26 - 6475 Shift assembly - Dismantling and assembly
Right-hand drive, Model 601, 602,611 (from Vehicle Ident. End No. 941 506)
1 Circlip check, replace as necessary 2 Cover 3 Washer 4 Lock washer 5 Shim ring 6 Spring washer check, replace as necessary 7 Spring ring 8 Shim 9 Spring washer check, replace as necessary 10 Spring washer check, replace as necessary 11 Shim 12 4th/5th gear lever check, replace as necessary 13 2nd/3rd gear lever check, replace as necessary 14 1st/reverse gear lever check, replace as necessary 15 Spacer sleeve check, replace as necessary 16 Shift gate check, replace as necessary 17 Washer check, replace as necessary 18 Shift gate check, replace as necessary 19 Circlip check, replace as necessary 20 Circlip check, replace as necessary 21 Washer check, replace as necessary 22 Spring check, replace as necessary 23 Shim ring 24 Spring check, replace as necessary 25 Circlip check, replace as necessary | 26 Bushing check, replace as necessary 27 Base assembly housing check, replace as necessary 28 Nut 29 Reverse gear switch check, replace as necessary 30 Spring washer 31 Bolt 32 Circlip check, replace as necessary 33 Washer 34 Bushing check, replace as necessary 35 Circlip check, replace as necessary 36 Shift shaft check, replace as necessary, grease 37 PIn check, replace as necessary 38 PIn check, replace as necessary 39 Cover 40 Shift lever grease 41 Dust cap 42 Circlip check, replace as necessary 43 Bearing check, replace as necessary 44 PIn 45 PIn 46 Bearing check, replace as necessary 47 Spring check, replace as necessary 48 Bushing check, replace as necessary |
Dismantling
1 Remove cover (39) and dust cap (41).
2 Remove circlip (42), then extract upper bearing half (43).
3 Remove shift lever (40).
4 Press out pins (44, 45).
Note
Press down lower bearing half (46), under tension.
5 Remove lower bearing half (46) together with spring (47).
6 Extract circlip (1) and remove cover (2).
7 Remove circlip (4) and take out shim ring (5).
8 Remove washer (3), spring washer (6) and spring ring (7).
9 Remove circlip (19) from the shift shaft (36); remove circlip (20) from base assembly housing (27).
Note
Circlips and washer are under spring pressure.
10 Remove washer (21), springs (22, 24) and shim ring (23).
11 Remove reversing lamp switch (29).
12 Remove circlip (35)
13 Extract shift shaft (36) together with plastic bushing (34), washer (33) and circlip (32).
14 Remove levers (12, 13, 14), washers (8, 11) and spring washers (9, 10) from the base assembly housing.
15 Remove spacer sleeve (15) with shift gates (16, 18) and washer (17).
Note
Note installation position of shift gates (16, 18).
16 Remove circlip (25) and plastic bushing (26).
17 Press the pins (37, 38) from the shift shaft (36).
18 Remove the circlip (32) from the shift shaft; remove washer (33), plastic bushing (34) and circlip (35).
19 Inspect all components, noting both general condition and any particular signs of wear; install new parts as necessary.
Assembly
1 Slide circlip (35), plastic bushing (34) and washer (33) onto the shift shaft, then insert circlip (32) and the pins (37, 38).
2 Install plastic bushing (26) and circlip (25) in the base assembly housing.
3 Insert spacer sleeve (15) with shift gates (16, 18) and washer (17) in the base assembly housing.
Note
Ensure that shift gates (16, 18) are installed in correct position.
4 Insert washers (8, 11), spring washers (9, 10) and levers (12, 13, 14) in the base assembly housing.
5 Guide in shift shaft. Align washers with spring washer and lever with the shift shaft.
6 Pull out the shift shaft (36), then insert from the opposite side.
7 Install circlip (35).
8 Install reversing lamp switch (29).
9 Slide shim ring (23), springs (22, 24) and washer (21) onto the shift shaft, then insert circlip (20) in the base assembly housing.
10 Push back shift shaft and insert circlip (19) in shaft.
11 Install spring ring (7), spring washer (6) and washer (3).
Note
Install spring washer with the convex side toward the outside.
12 Install shim ring (5) on the shift shaft (5), then insert lock washer (4).
13 Install cover (2) and circlip (1).
14 Install spring (47) and lower bearing half (46).
15 Compress lower bearing half (46) and install both pins (44, 45).
Note
Ensure that Dimension"a" = 21 + 0.5 mm is correct.
16 Install shift lever (40).
17 Install upper bearing half (43) with circlip (42).
18 Install cover (39) and dust cap (41).