716 589 01 33 00
Drift
Sleeve
Sleeve
716 589 02 33 00
711 589 07 15 00
Commercially available tools
Number | Designation | |
WH58.30-Z-1008-02A | Circlip pliers for external circlip | |
WH58.30-Z-1004-12A | Feeler gauge |
D26.50-1142-01
Different gearwheels are fitted in diesel and gasoline vehicles
(with the exception of gearwheels for 1st gear and reverse gear.
In order to distinguish between the gearwheels, the gearwheels for diesel vehicles
(with the exception of the gearwheel for 1st gear and reverse gear) have a groove (arrow) in teeth.
When the new synchronizer bodies are pressed on shavings can occur which have to be removed.
Use compressed air to blow off the main shaft.
D26.50-1169-01
1 Clamp main shaft (27) in the vise, using protective material in the jaws.
Input end uppermost.
2 Install 6th gear needle bearing (28).
3 Install 6th gearwheel (29).
The straight teeth must point upwards (towards the input end).
D26.50-1168-01
4 Install clutch body (30).
The outer teeth must point downwards (towards the output end).
5 Install synchronizer ring (31).
The teeth must point downwards (towards the output end).
D26.50-1198-12
New synchronizer units are supplied assembled.
6 Push sliding sleeve (36) onto 5th/6th gear synchronizer body (32).
Slide on the sliding sleeve (36) so that the balls (35) then engage in the center groove of the sliding sleeve teeth (arrow).
7 Install the narrow sliders (34), thrust springs (33) and balls (35) in the 5th/6th gear synchronizer body (32).
The widths of the sliders used for the individual synchronizer bodies vary:
1st/2nd gear synchronizer body: Wide sliders (15 mm)
3rd/4th gear synchronizer body: Wide sliders (15 mm)
5th/6th gear synchronizer body: narrow sliders (9 mm)
Reverse gear synchronizer body: narrow sliders (9 mm)
D26.50-1171-01
8 Press on 5th/6th gear (52) using sleeve.
The writing on the synchronizer body must point upwards (towards the input end).
The drivers on the synchronizer ring (31) must engage in the grooves in the synchronizer body.
D26.50-1172-01
9 Determine thickness of the circlip (39):
- Insert test ring (thickness: 1.5 mm) with pliers and press completely downwards (towards output).
- Measure distance between test ring and top edge of groove in the main shaft (27) using feeler gauge.
- Thickness of circlip = measured value + 1.5 mm (test ring).
- Remove test ring using pliers.
10 Use pliers to insert new circlip (39) with thickness determined.
(graduation: 0.05 mm).
Do not over-expand the circlip. Ensure that the circlip is properly seated.
D26.50-1173-01
11 Install synchronizer ring (37).
The drivers on the synchronizer ring (37) must engage in the grooves in the 5th/6th gear synchronizer body.
12 Install clutch body (38).
The straight teeth must point upwards (towards the input end).
D26.50-1174-01
13 Oil cylindrical roller bearing (40) and place in input shaft (41).
14 Place input shaft (41) on main shaft.
15 Remove the main shaft with the input shaft (41) from the vise, turn it and clamp the input shaft (41) in the vise, placing a protective cushioning material between it and the jaws.
D26.50-1165-01
16 Mount 2nd gear needle roller bearing (26).
17 Mount 2nd gear idler gear (25).
The collar must face upwards (towards the output end).
D26.50-1164-01
18 Install the friction ring (24).
The lobes must face upward (towards the output end).
19 Install synchronizer cone ring (23).
The lobes in the cone ring (23) must engage with the recesses in the 2nd gear idler gear.
20 Install synchronizer ring (22).
The teeth must point downwards (towards the input end).
The lobes in the friction ring (24) must engage in the recesses in the synchronizer ring (22).
D26.50-1206-05
New synchronizer units are supplied assembled.
21 Slide sliding sleeve (17) onto 1st/2nd gear synchronizer body (18).
Slide on the sliding sleeve (17) so that the balls (21) then engage in the center groove of the sliding sleeve teeth (arrow).
22 Install wide sliders (20), thrust springs (19) and balls (21) in the 1st/2nd gear synchronizer body (18).
D26.50-1207-12
23 Install new 1st/2nd gear synchronizer unit (51) and press on using sleeve.
The detection groove (bottom groove) of the sliding sleeve must point downwards (towards the input end) If the sliding sleeve is installed twisted, 1st gear may jump out.
The cams (top arrow) of the synchronizer ring must engage in the cutouts of the 1st/2nd gear synchronizer body.
D26.50-1177-01
24 Determine thickness of the circlip (16):
- Insert test ring (thickness: 1.5 mm) using pliers and press downwards completely (towards the input end).
- Measure distance between the test ring and upper edge of the groove in the main shaft using a feeler gauge .
- Thickness of circlip = Measured value + 1.5 mm (test circlip).
- Remove test ring using pliers.
25 Use pliers to insert new circlip (16) with thickness determined. (graduation: 0.05 mm).
Do not over-expand the circlip. Ensure that the circlip is properly seated.
D26.50-1162-01
26 Install synchronizer ring (15).
The teeth must point upwards (towards the output end).
27 Install synchronizer cone ring (14).
The lobes must face upward (towards the output end).
28 Install the friction ring (13).
The lobes on the friction ring (13) must engage with the cutouts in the synchronizer ring (15).
D26.50-1161-01
29 Mount 1st gear needle roller bearing (12).
30 Mount 1st gear idler gear (11).
The cone must point downwards (towards the input end). The lobes (arrow) in the synchronizer ring must engage with the recesses in the 1st gear idler gear (11).
31 Install thrust washer (10) and press on with sleeve .
D26.50-1160-01
32 Press on sleeve (9) with drift.
33 Install reverse gear switch (8).
D26.50-1159-01
34 Install reverse gearwheel (7).
The collar must face upwards (towards the output end).
35 Install synchronizer ring (6).
The teeth must point downwards (towards the input end).
D26.50-1178-01
New synchronizer units are supplied assembled.
36 Push sliding sleeve (1) onto reverse gear synchronizer body (2).
The closed side of the grooves in the reverse gear synchronizer body (2) must point downwards.
Slide on sliding sleeve (1) so that the pointed sides of the tooth flanks point upwards and the balls (5) then engage in the center groove of the sliding sleeve toothing (arrow).
D26.50-1144-01
37 Install the narrow sliders (4), thrust springs (3) and balls (5) in the reverse gear synchronizer body (2).
D26.50-1158-01
38 Mount reverse gear synchonizer assembly (50) and press on with sleeve.
The lobes of the synchronizer ring must engage in the grooves of the reverse gear synchronizer body.
39 Remove input shaft together with main shaft from vise.