Disassemble and assemble main shaft

AR26.50-B-0420DT

Disassemble and assemble main shaft

29.07.2019

Transmission

712.820/830 in model 963

1

Nut

13

Needle roller bearing

2

Front tapered roller bearing

14

Main shaft

3

Adjustment shim

15

1st gear

4

Synchronizer sleeve

16

Needle roller bearing

5

Synchronizer ring

17

Synchronizer body

6

Taper roller bearing

18

Thrust ring

7

Constant gear 2

19

Synchronizer sleeve

8

Taper roller bearing

20

Needle roller bearing

9

Synchronizer sleeve

21

Bushing

10

Lock-ring

22

Reverse idler gear

11

Synchronizer body

23

Tapered roller bearing with pulse wheel

12

3rd gear



Disassemble

1

Remove the tapered roller bearing with pulse wheel (23) and the reverse idler gear (22)

 Be sure to properly support the spindle puller claws on the reverse idler gear (22). Be careful not to damage it.

 Support the main shaft in a suitable device and be careful not to damage the gears.

 Bathe the tapered roller bearing (23) in oil and wrap it with a clean, lint-free cloth or paper, to protect it until the moment of assembly.

 disassembly kit

*715589196300

 Hydraulic cylinder

*715589153400

 Adapter

*715589123400

 Adapter

*715589113400

 Adapter

*715589103400

 Puller without spindle

*715589023315

 Hydraulic hose (complete)

*652589003323

 Hand pump

*652589003321

2

Remove needle bearing (20)

 Bathe the needle bearing (20) in oil and wrap it with a clean, lint-free cloth or paper, to protect it until the moment of assembly.

3

Position the main shaft (14) with the nut side (1) facing up

 Clamping device

*315589023100

4

Remove the nut (1) of the main shaft (14)


Be careful when removing the nut (1).
For there is a high risk of accident from the sudden release torque.

5

Remove the front tapered roller bearing (2)

 Bathe the front tapered roller bearing (2) in oil and wrap it with a clean, lint-free cloth or paper, to protect it until the moment of assembly.

 disassembly kit

*715589196300

 Hydraulic cylinder

*715589153400

 Adapter

*715589123400

 Adapter

*715589113400

 Hydraulic hose (complete)

*652589003323

 Hand pump

*652589003321

 Gripper

*715589073400

6

Remove the adjustment shim (3)

7

Remove the constant gear 2 (7) along with the tapered roller bearing (6)

 Be sure to properly support the spindle puller claws on the reverse idler gear 2 (7). Be careful not to damage it.

 Bathe the front tapered roller bearing (6) in oil and wrap it with a clean, lint-free cloth or paper, to protect it until the moment of assembly.

 disassembly kit

*715589196300

 Hydraulic cylinder

*715589153400

 Adapter

*715589123400

 Adapter

*715589113400

 Adapter

*715589103400

 Puller without spindle

*715589023315

 Hydraulic hose (complete)

*652589003323

 Hand pump

*652589003321

8

Remove the tapered roller bearing (8) from the constant gear 2 (7)

 Bathe the lower tapered roller bearing (8) in oil and wrap it with a clean, lint-free cloth or paper, to protect it until the moment of assembly.

 Gripper

*715589243400

 disassembly kit

*715589196300

 Hydraulic cylinder

*715589153400

 Adapter

*715589123400

 Adapter

*715589113400

 Hydraulic hose (complete)

*652589003323

 Hand pump

*652589003321

9

Remove the synchronizer sleeve (9)

10

Remove the retaining ring (10) from the synchronizer body (11)

11

Remove the synchronizer body (11)

12

Remove the 3rd speed gear (12)

13

Remove the needle bearing (13)

 Bathe the needle bearing (13) in oil and wrap it with a clean, lint-free cloth or paper, to protect it until the moment of assembly.

14

Place the main shaft (14) in a press

 Place the 1st gear (15) on the workshop press with the main shaft rear side (14) upwards.

15

Press the main shaft (14) downwards

16

Remove along: 1st speed gear (15), the synchronizer ring (17), thrust ring (18) and the bushing (21)

17

Remove needle bearing (16)

 Bathe the needle bearing (16) in oil and wrap it with a clean, lint-free cloth or paper, to protect it until the moment of assembly.



Check

18

Check gears for wear

If the gear teeth have worn or cracked areas:



Replace the damaged gear by a new one.

19

Check the bearings

 Inspect all rollers and needles for wear, chipping or cracking.

If the bearing shows any defect or wear:



Replace this with a new one.

 If the tapered roller bearing is replaced by a new one, the respective bearing cover on the transmission housing will also have to be replaced.

20

Check the main shaft (14) for damages or wear

If the main shaft (14) shows wear, damaged splines or warping:



Replace the main shaft (14) with a new one.



Assemble

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

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

AS00.00-Z-0002-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

21

Assemble the needle bearing (16) with the 1st speed gear (15) in the main shaft (14)

 Lubricate the needle bearing (16) using oil.

22

Assemble the synchronizer body (17)

 Pay attention to the correct positioning of the synchronizer body (17). The undercut side should be up.

23

Assemble the thrust ring (18)

24

Heat the bushing (21) and assemble in the main shaft (14)

 Heat the bushing (21) to approximately 100ºC. Make sure the bushing is correctly seated (21) in the thrust ring (18).

25

Turn the main shaft (14) in the device with rear part downwards

26

Mount the needle bearing (13)

 Lubricate the needle bearing (13) using oil.

27

Mount the 3rd speed gear (12)

28

Mount the synchronizer body (11) in the main shaft (14)

 Pay attention to the correct positioning of the synchronizer body (11). The undercut side should be up.

29

Determine the retaining ring (10) thickens and install into the main shaft channel (14)

.

AR26.50-B-0426-02DT

 Use a new retaining ring (10).

30

Mount the synchronizer sleeve (9)

31

Mount the tapered roller bearing (8)

 Heat the tapered roller bearing (8) to approximately 80 ºC. Make sure the tapered roller bearing is correctly seated (8) into the main shaft (14).

32

Assemble the constant gearwheel 2 (7)

33

Mount the tapered roller bearing (6)

 Heat the tapered roller bearing (6) to approximately 80ºC. Make sure the tapered roller bearing is correctly seated (6) into the main shaft (14).

34

Determine the adjustment shim (3) and install into the main shaft (14)

.

AR26.50-B-0420-11DT

35

Install the front tapered roller bearing (2)

 Heat the front tapered roller bearing (2) to approximately 80ºC. Make sure it is correctly seated to the main shaft (14).

 Lubricate the front tapered needle bearing (2) using oil.

36

Install the nut (1) in the main shaft (14)

 Use a new nut (1).

 .Secondary shaft nut

*BA26.10-B-1011-01MB

37

Place the main shaft (14) with front part downwards

38

Mount the synchronizer sleeve (19)

39

Assemble the reverse idler gear (22) needle bearing (20)

 Lubricate the needle bearing (20) using oil.

40

Mount the reverse idler gear (22)

41

Install the tapered roller bearing with pulse wheel (23) in the main shaft (14)

 Heat the tapered roller bearing with pulse wheel (23) to approximately 80ºC. Make sure it is correctly seated to the main shaft (14).

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BA26.10-B-1011-01MB

Secondary shaft nut

Nm

340