Disassemble/assemble transmission housing

AR26.40-D-2002R

Disassemble/assemble transmission housing

13.03.2020

Transmission

711.680/683 in model 909

1

Roller bearing

2

Cap

3

Screw

4

Inner bearing race

5

Drive shaft

6

Pilot bushing

7

Front section of transmission housing

8

Screw

9

Rear section of transmission housing

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A



Remove

1

Remove transmission and secure to assembly stand.

AR26.10-D-0036R



Disassemble

2

Unscrew screws (8) except two opposite screws (8).

3

Turn transmission, until drive shaft (5) points upwards.

4

Unscrew remaining screws (8).

5

Pierce cap (2) in the center and pry out.


When removing, do not position lever between cap (2) and seat.
If the seat is damaged, the front section of the transmission housing (7) must be replaced.

6

Counterhold drive shaft (5) with retainer wrench and remove screw (3).

 Retainer wrench

*716589000900

7

Remove front section of transmission housing (7).

AR26.40-D-2470-01R

 Extraction tool

*711589023300

8

Remove drive-side inner bearing race (4).

 The inner bearing race (4) of the countershaft bearing is divided into two halves. The output side inner bearing race (4) sits on the countershaft.

9

Remove roller bearing (1) and check condition, replace if necessary.


The bearing cage of the new roller bearing (1) must be the same color as the bearing cage of the removed roller bearing (1).
Otherwise the drive shaft (5) or the main shaft could be damaged.

 The roller bearing (1) is supplied with a white or black bearing cage.



Assemble

10

Clean sealing surfaces of transmission housing parts (7, 9).


The sealing surface should be free of grease and dust.
Otherwise there may be adhesion problems.

Assembly cleaner

*BR00.45-Z-1028-04A

11

Check pilot bushings (6) are seated correctly; secure if necessary.

12

Apply sealant evenly on sealing surfaces of front section of transmission housing (7).

Loctite 5203 sealant

*BR00.45-Z-1015-01A

13

Install roller bearing (1).

14

Position front section of transmission housing (7) on main shaft and countershaft.

15

Attach front section of transmission housing (7).

AR26.40-D-2470-08R

 Insertion tool

*711589024300

 Extraction tool

*711589023300

16

Tighten screws (8) evenly in a crosswise pattern.

 Screw/bolt, front section of transmission housing to rear section of transmission housing

*BA26.40-N-1008-01A

17

Insert drive-side inner bearing race (4).

18

Counterhold drive shaft (5) with retainer wrench and tighten screw (3).

 Screw/bolt, countershaft to countershaft bearing

*BA26.50-N-1005-01D

 Retainer wrench

*716589000900

19

Install new cap (2).

 The cap (2) must close flush and evenly all-round.

 Drift

*124589051500



Install

20

Remove transmission from assembly stand and install.

AR26.10-D-0036R

 Transmission housing

Number

Designation

Transmission 711.680

Transmission 711.683 in model 909

BA26.40-N-1008-01A

Screw/bolt, front section of transmission housing to rear section of transmission housing

Nm

33

33

 Gear set, shafts

Number

Designation

Transmission 711.680

Transmission 711.683

BA26.50-N-1005-01D

Screw/bolt, countershaft to countershaft bearing

M14x1.5

Nm

-

-

M18x1.5

Nm

100

100

Repair materials

Number

Designation

Order number

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01