Disassemble and assemble main shaft

AR26.50-T-0420A

Disassemble and assemble main shaft

9.10.06

23.12.04

Note added: Mark installation position of 1st and 2nd gear sliding sleeve (12)

Step 7

Note added: Mark installation position of 5th and 6th gear sliding sleeve (25)

Step 15

Note added: Mark installation position of 3rd and 4th gear sliding sleeve (38)

Step 21

 

Disassemble/assemble

 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

1

Disassemble transmission

 Disassemble the transmission only until the main shaft (1) can be removed.

AR26.10-T-0001A

2

Detach reverse gear wheel (4) and reverse gear wheel needle cage (2)

 Assembly: Oil needles of reverse gear wheel needle cage (2).

3

Detach reverse gear sliding sleeve (6)

 Mark installation position of reverse gear sliding sleeve (6).

 Assembly: Observe marking on reverse gear sliding sleeve (6) to determine the installation position.

4

Pull reverse gear wheel bush (3) and reverse gear synchronizer body (5) off main shaft (1) together with 1st gear wheel (8) and 1st gear synchronizer cone (9)

 Assembly: Heat reverse gear wheel bush (3) to approx. 120 °C before pushing onto the main shaft (1).

5

Detach 1st gear wheel needle cage (7)

 Assembly: Oil needles of 1st gear wheel needle cage (7).

6

Detach circlip (13) of 1st and 2nd gear synchronizer body (11) from main shaft (1)

7

Detach 1st and 2nd gear sliding sleeve (12) and 1st and 2nd gear synchronizer body (11)

 Mark installation position of 1st and 2nd gear sliding sleeve (12).

 Assembly: Observe marking on 1st and 2nd gear sliding sleeve (12) to determine the installation position.

8

Detach 2nd gear wheel (15) and 2nd gear synchronizer cone (16)

9

Detach 2nd gear wheel needle cage (14)

 Assembly: Oil needles of 2nd gear wheel needle cage (14).

10

Remove circlip (18)

11

Detach thrust plate (19) from main shaft (1)

 Heat the thrust plate (19) using a hot air gun if necessary.

12

Pull off cylindrical roller bearing inner race (20) using puller

 Heat the cylindrical roller bearing inner race (20) using a hot air gun if necessary.

 Assembling:

 Heat cylindrical roller bearing inner race (20) to approx. 120 °C and fit on main shaft (1).

 Then oil external surface of cylindrical roller bearing inner race (20).



*001589193300

13

Detach 6th gear synchronizer ring (21) with 6th gear synchronizer cone (22)

14

Remove circlip (26) from 5th and 6th gear synchronizer body (24)

15

Detach 5th and 6th gear sliding sleeve (25) and 5th and 6th gear synchronizer body (24)

 Mark the installation position of the 5th and 6th gear sliding sleeve (25).

 Assembly: Observe the marking on the 5th and 6th gear sliding sleeve (25) to determine the installation position.

16

Detach 5th gear wheel (28) with 5th gear synchronizer ring (30) and 5th gear synchronizer cone (29)

17

Detach 5th gear wheel needle cage (27)

 Assembly: Oil the needles of the 5th gear wheel needle cage (27).

18

Detach 4th gear wheel (33) with 4th gear synchronizer ring (34) and 4th gear synchronizer cone (35)

19

Detach 4th gear wheel needle cage (32)

 Assembly: Oil the needles of the 4th gear wheel needle cage (32).

20

Remove circlip (39) from 3rd and 4th gear synchronizer body (37)

21

Detach 3rd and 4th gear sliding sleeve (38) and 3rd and 4th gear synchronizer body (37)

 Mark the installation position of the 3rd and 4th gear sliding sleeve (38).

 Assembly: Observe the marking on the 3rd and 4th gear sliding sleeve (38) to determine the installation position.

22

Detach 3rd gear wheel (41) and 3rd gear synchronizer cone (42)

23

Detach 3rd gear wheel needle cage (40)

 Assembly: Oil the needles of the 3rd gear wheel needle cage (40).

24

Disassemble 1st gear synchronizer



 Detach annular spring (10) from 1st gear wheel (8).

 Detach 1st gear synchronizer cone (9) from 1st gear wheel (8).

25

Disassemble 2nd gear synchronizer



 Detach annular spring (17) from 2nd gear wheel (15).

 Detach 2nd gear synchronizer cone (16) from 2nd gear wheel (15).

26

Disassemble 3rd gear synchronizer



 Detach annular spring (43) from 3rd gear wheel (41).

 Detach 3rd gear synchronizer cone (42) from 3rd gear wheel (41).

27

Disassemble 4th gear synchronizer



 Press 4th gear synchronizer ring (34) off 4th gear wheel (33).

 Press annular spring (36) off 4th gear synchronizer ring (34) and detach.

 Detach 4th gear synchronizer cone (35) from 4th gear synchronizer ring (34).

28

Disassemble 5th gear synchronizer

 There may be a spacer washer (44) between the 5th gear wheel (28) and the 5th gear synchronizer ring (30).

 Press 5th gear synchronizer ring (30) off 5th gear wheel (28).

 Press off and detach annular spring (31) from 5th gear synchronizer ring (30).

 Detach 5th gear synchronizer cone (29) from 5th gear synchronizer ring (30).

29

Disassemble 6th gear synchronizer



 Press off and detach annular spring (23) from 6th gear synchronizer ring (21).

 Detach 6th gear synchronizer cone (22) from 6th gear synchronizer ring (21).

30

Clean all parts and check for wear, renew if necessary.

31

Assemble in the reverse order