Remove/install main shaft and countershaft with shift unit · ar2650d0002a · Mercedes-Benz WIS

AR26.50-D-0002A

Remove/install main shaft and countershaft with shift unit

04.06.2018

Transmission	711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990
Transmission	711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990
Transmission	711.670 in model 204 with engine 642, 651
Transmission	711.670 in model 207 with engine 651

Remove/install main shaft and countershaft with shift unit

Transmission 711.660 shown

1	Puller
2	Rear section of transmission housing
3	Intermediate plate
4	Support fixture
5	Shift unit
6	Thrust piece
7	Gearshift lever
8	Bolt with washer
9	Pull-in sleeve (kit, 3-piece)
S164	Transmission neutral position switch

D26.40-1165-06

Transmission 711.660 shown

3	Intermediate plate
4	Support fixture
5	Shift unit
10	Main shaft
11	Countershaft
12	Arrester
13	Support slides
14	Support slides

D26.60-1200-12

	Remove
1	Remove transmission	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990	AR26.10-D-0020G
		Transmission 711.670 in model 207 with engine 651	AR26.10-P-0020CWA
		Transmission 711.670 in model 204 with engine 642, 651	AR26.10-P-0020SA
2	Fasten transmission on assembly stand		AR26.10-D-0036A
3	Remove central clutch release bearing	Transmission 711.670 in model 204 with engine 642, 651 Transmission 711.670 in model 207 with engine 651	AR26.40-P-0345CW
4	Remove output flange	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 except code ZG1 (Engageable all-wheel drive) except code ZG2 (Permanent all-wheel drive) except code ZG3 (Engageable all-wheel drive with gear reduction) except code ZG4 (Permanent all-wheel drive with gear reduction)	AR26.40-D-2475-03A
		Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code ZG1 (Engageable all-wheel drive) Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code ZG2 (Permanent all-wheel drive) Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code ZG3 (Engageable all-wheel drive with gear reduction) Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code ZG4 (Permanent all-wheel drive with gear reduction)	AR26.40-D-2475-03B
		Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651	AR26.40-P-2475-03CW
		 Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651 Puller	*129589013300
		 Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651 Adapter	*100589025900
		 Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651 Socket wrench bit	*126589020900
		 Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651 Pin wrench	*129589010700
		 Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 Puller	*000589653300
		 Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 bei ausgebautem GetriebeTransmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990bei ausgebautem Getriebe Retainer wrench	*716589000900
		 Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 except code ZG1 (Engageable all-wheel drive) except code ZG2 (Permanent all-wheel drive) except code ZG3 (Engageable all-wheel drive with gear reduction) except code ZG4 (Permanent all-wheel drive with gear reduction) Pin wrench	*901589000700
5	Disassemble transmission housing		AR26.40-D-2002D
6	Detach gear set with rear section of transmission housing (2) from assembly stand
7	Insert gear set with rear section of transmission housing (2) in support fixture (4).		AR26.40-D-2475-07A
		 Support fixture	*711589014000
8	Remove grooved pin from gearshift lever (7) and remove gearshift lever (7)
9	Remove transmission neutral switch (S164)	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990
10	Remove thrust piece (6)	 Impact extractor	*355589016300
		 Extraction claw	*715589063300
11.1	Unscrew shift unit (5)	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990
			AR26.40-D-2475-06A
11.2	Unscrew shift unit (5) and intermediate plate (3)	Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 Transmission 711.670 in model 204 with engine 642, 651 Transmission 711.670 in model 207 with engine 651
			AR26.40-D-2475-06A
12	Detach rear section of transmission housing (2) from gear set	 Position the  jaws, padding them with pieces of wood or plastic. Otherwise, the sealing surface of the rear section of the transmission housing (2) will be damaged.
		 Puller	*000589653300
		 Gripper	*000589873300
13	Slide support slide (14) outwards and remove shift unit (5)
14.1	Release locking device (12), slide support slide (13) outwards and remove countershaft (11)	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990
14.2	Remove intermediate plate (3) and remove countershaft (11)	Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 Transmission 711.670 in model 204 with engine 642, 651 Transmission 711.670 in model 207 with engine 651
			AR26.40-D-0330-08A
		 Support fixture	*711589014000
15	Remove main shaft (10)	 For disassembling, leave the main shaft (10) in support fixture (4).
16	Remove synchronizer ring and clutch body (arrow)	Transmission 711.670 in model 204 with engine 642, 651 Transmission 711.670 in model 207 with engine 651
17	Remove radial shaft sealing ring and bearing for main shaft (10)		AR26.40-D-2476D
		 The radial shaft sealing ring and the bearing must always be replaced.
	Install
18	Install new bearing and new radial shaft sealing ring for main shaft (10)		AR26.40-D-2476D
19	Mount synchronizer ring and clutch body (arrow) on the 5th/6th gear synchronizer unit	 Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 Only necessary if the synchronizer ring and the clutch body (arrow) have been released from the 5th/6th gear synchronizer unit.
		 The synchronizer ring drivers must engage in the grooves of the 5th/6th gear synchronizer unit.
20	Insert main shaft (10) and countershaft (11) in support fixture (4)	 Support fixture	*711589014000
21.1	Slide mounting slide (13) inwards and fix in place with locking device (12)	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990
21.2	Install intermediate plate (3)	Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 Transmission 711.670 in model 204 with engine 642, 651 Transmission 711.670 in model 207 with engine 651
			AR26.40-D-0330-09A
		 Screw/bolt, mounting plate half to mounting plate half	*BA26.50-N-1009-01D
		 Support fixture	*711589014000
		 Positioning device	*711589053100
22	Insert shift unit (5) into the support slides (14)
23	Slide support slide (14) inward as far as end stop.	 When moving in the shift unit (5) ensure that the sliding sleeve engages evenly in the sliding sleeves of the shift units.
24	Attach rear section of transmission housing (2) to gear set
25	Move the countershaft (11) to and fro until it engages detectably in the toothing of the power take-off	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 with code N05 (Power take-off countershaft (2c) without flange) Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 with code N07 (Power take-off countershaft (2b) with flange) Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code N05 (Power take-off countershaft (2c) without flange) Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code N07 (Power take-off countershaft (2b) with flange)
26	Block the main shaft (10) and countershaft (11) with a lint-free rag	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990
27	Pull rear section of transmission housing (2) onto main shaft (10)	 Match number and height of  pulling-in sleeves (9) when pulling in. Otherwise, the threads will be damaged.
		 Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 Use bolt with shim (8) of output flange.
		 Transmission 711.670 in model 204 with engine 642, 651 Transmission 711.670 in model 207 with engine 651 Use collar nut of output flange and box wrench. Counterhold output shaft using Torx wrench.
		 Insertion sleeves	*716589003300
28	Detach bolt with shim (8) or collar nut and pull-in sleeves (9)
29	Remove rags	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990
30.1	Bolt on shift unit (5)	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990
			AR26.40-D-2475-06A
		 Screw/bolt, shift unit to transmission housing rear section	*BA26.50-N-1010-01D
30.2	Screw on shift unit (5) and intermediate plate (3)	Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 Transmission 711.670 in model 204 with engine 642, 651 Transmission 711.670 in model 207 with engine 651
			AR26.40-D-2475-06A
		 Screw/bolt, shift unit to transmission housing rear section	*BA26.50-N-1010-01D
		 Screw/bolt, mounting plate to transmission housing	*BA26.50-N-1008-01D
31	Drive in thrust piece (6) as far as the end stop
32	Mount transmission neutral switch (S164)	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990
		 Bolt, neutral position switch	*BA26.19-N-1008-01B
33	Mount gearshift lever (7)	 Replace grooved pin.
34	Remove gear set with rear section of transmission housing (2) from support fixture (4)
35	Attach gear set with rear section of transmission housing (2) to assembly stand		AR26.10-D-0036A
36	Assemble transmission housing		AR26.40-D-2002D
37	Install output flange	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 except code ZG1 (Engageable all-wheel drive) except code ZG2 (Permanent all-wheel drive) except code ZG3 (Engageable all-wheel drive with gear reduction) except code ZG4 (Permanent all-wheel drive with gear reduction)	AR26.40-D-2475-03A
		Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code ZG1 (Engageable all-wheel drive) Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code ZG2 (Permanent all-wheel drive) Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code ZG3 (Engageable all-wheel drive with gear reduction) Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 with code ZG4 (Permanent all-wheel drive with gear reduction)	AR26.40-D-2475-03B
		Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651	AR26.40-P-2475-03CW
		 Transmission 711.670 in model 204 with engine 642, 651 Transmission 711.670 in model 207 with engine 651Collared nut, output flange to main shaft	*BA26.10-P-1004-01F
		 Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651Nut, output flange to main shaft	*BA26.50-N-1001-01D
		 Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990Screw/bolt, output flange to main shaft	*BA26.50-N-1006-01D
		 Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990 except code ZG1 (Engageable all-wheel drive) except code ZG2 (Permanent all-wheel drive) except code ZG3 (Engageable all-wheel drive with gear reduction) except code ZG4 (Permanent all-wheel drive with gear reduction) Pin wrench	*901589000700
		 Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 bei ausgebautem GetriebeTransmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990bei ausgebautem Getriebe Retainer wrench	*716589000900
		 Puller	*000589653300
		 Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651 Puller	*129589013300
		 Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651 Adapter	*100589025900
		 Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651 Socket wrench bit	*126589020900
		 Transmission 711.670 in model 204.0/2/3 with engine 642, 651 Transmission 711.670 in model 207 with engine 651 Pin wrench	*129589010700
38	Install central clutch release bearing	Transmission 711.670 in model 204 with engine 642, 651 Transmission 711.670 in model 207 with engine 651	AR26.40-P-0345CW
39	Detach transmission from assembly stand
40	Install transmission	Transmission 711.651 in model 906.1/2/6/7 with engine 646.984/985/986/989/990 Transmission 711.660 in model 906.1/2/6/7 with engine 642.992, 646.985/986/989/990	AR26.10-D-0020G
		Transmission 711.670 in model 204 with engine 642, 651	AR26.10-P-0020SA
		Transmission 711.670 in model 207 with engine 651	AR26.10-P-0020CWA

 Manual transmission complete

Number	Designation				Transmission 711.67
BA26.10-P-1004-01F	Collared nut, output flange to main shaft	M26	Stage 1	Nm	200
			Stage 2		lösen
			Stage 3	Nm	160

 Sensors, transmitters

Number	Designation		Transmission 711.651/660
BA26.19-N-1008-01B	Bolt, neutral position switch	Nm	9

 Gear set, shafts

Number	Designation				Transmission 711.670
BA26.50-N-1001-01D	Nut, output flange to main shaft	M12x1.5		Nm	-
		M24x1.5	Stage 1	Nm	200
			Stage 2	Nm	lösen
			Stage 3	Nm	160
		M26x1.5	Stage 1	Nm	-
			Stage 2, loosen	Nm	-
			Stage 3	Nm	-

 Gear set, shafts

Number	Designation		Transmission 711.651	Transmission 711.660
BA26.50-N-1006-01D	Screw/bolt, output flange to main shaft	Nm	110	110

 Gear set, shafts

Number	Designation		Transmission 711.660	Transmission 711.670
BA26.50-N-1008-01D	Screw/bolt, mounting plate to transmission housing	Nm	28	28

 Gear set, shafts

Number	Designation		Transmission 711.660	Transmission 711.670
BA26.50-N-1009-01D	Screw/bolt, mounting plate half to mounting plate half	Nm	50	50

 Gear set, shafts

Number	Designation			Transmission 711.651	Transmission 711.660
BA26.50-N-1010-01D	Screw/bolt, shift unit to transmission housing rear section	M6	Nm	9	9

 Gear set, shafts

Number	Designation			Transmission 711.670
BA26.50-N-1010-01D	Screw/bolt, shift unit to transmission housing rear section	M6	Nm	9

129 589 01 33 00

Puller

711 589 01 40 00

Support fixture

715 589 06 33 00

Extraction claw

000 589 65 33 00

Puller

000 589 87 33 00

Gripper

129 589 01 07 00

Pin wrench

716 589 00 09 00

Retainer wrench

901 589 00 07 00

Pin wrench

716 589 00 33 00

Insertion sleeves

355 589 01 63 00

Impact extractor

711 589 05 31 00

Positioning device

126 589 02 09 00

Socket wrench bit

100 589 02 59 00

Adapter

Referenced documents

ar2610d0020g Remove/install transmission
ar2610d0036a Fasten transmission on assembly stand
ar2610p0020cwa Remove/install transmission
ar2610p0020sa Remove/install transmission
ar2640d033008a Remove intermediate plate
ar2640d033009a Install intermediate plate
ar2640d2002d Disassemble/assemble transmission housing
ar2640d247503a Remove/install output flange
ar2640d247503b Remove/install output flange
ar2640d247506a Unscrew/screw on shift unit and intermediate plate
ar2640d247507a Insert gear set with rear section of transmission housing into support fixture
ar2640d2476d Disassemble/assemble rear section of transmission housing
ar2640p0345cw Remove/install central clutch operator
ar2640p247503cw Remove/install output flange