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
Diesel and gasoline-engine vehicles are fitted with different gear wheels
(with the exception of the gear wheels for 1st gear and reverse gear).
In order to distinguish between these gear wheels, those for diesel vehicles
(with the exception of the gear wheels for 1st gear and reverse gear) have a groove (arrow) in the teeth.
When pressing on new synchronizer bodies, swarf may be produced and this must be removed:
Use compressed air to blow off the main shaft.
D26.50-1165-01
1 Clamp main shaft in vise with protective jaws.
Input end at the bottom.
2 Install 2nd gear needle bearing (26).
3 Install idler gear for 2nd gear (25).
The collar must point upwards (towards the output end).
D26.50-1164-01
4 Install friction ring (24).
The lobes must point upwards (towards the output end).
5 Install cone ring (23).
The lobes on the cone ring (23) must engage in the recesses in the idler gear for 2nd gear.
6 Install synchronizer ring (22).
The teeth must point downwards (towards the input end).
The lobes on the friction ring (24) must engage in the recesses in the synchronizer ring (22).
D26.50-1175-12
New synchronizer units are supplied already assembled.
Only if necessary:
7 Assemble new synchronizer unit:
7.1 Push sliding sleeve (17) onto 1st/2nd gear synchronizer body (18).
The inscription on the synchronizer body (18) must face upwards. The orientation groove (arrow at top) on the sliding sleeve must point downwards.
When pushing on the sliding sleeve (17), align it to ensure that the balls (21) will subsequently engage in the center groove of the sliding sleeve teeth (arrow).
7.2 Install wide sliders (20), compression springs (19) and balls (21) in 1st/2nd gear synchronizer body (18).
D26.50-1176-11
8 Install new 1st/2nd gear synchronizer unit (51) and press on using sleeve.
The inscription on the synchronizer body must face upwards (towards the output end). The orientation groove on the sliding sleeve must point downwards (towards the input end).
The lobes (arrow) on the synchronizer ring must engage in the recesses in the 1st/2nd gear synchronizer body.
D26.50-1177-01
9 Determine thickness of locking ring (16):
- Insert trial locking ring (thickness: 1.5 mm) using pliers and press all the way down (towards the input end).
- Measure distance between trial locking ring and top edge of groove in main shaft using feeler gauge.
- Thickness of locking ring = measured value + 1.5 mm (trial locking ring).
- Remove trial locking ring using pliers.
10 Use pliers to install new locking ring (16) of the determined thickness
(increments: 0.05 mm).
Do not over-expand the locking ring. Ensure that the locking ring is properly seated.
D26.50-1162-01
11 Install synchronizer ring (15).
The teeth must point upwards (towards the output end).
12 Install cone ring (14).
The lobes must point upwards (towards the output end).
13 Install friction ring (13).
The lobes on the friction ring (13) must engage in the recesses in the synchronizer ring (15).
D26.50-1161-01
14 Install 1st gear needle bearing (12).
15 Install idler gear for 1st gear (11).
The cone must point downwards (towards the input end).
The lobes on the synchronizer ring must engage in the recesses in the idler gear for 1st gear (11).
16 Install thrust washer (10) and press on using sleeve.
D26.50-1160-01
17 Press on sleeve (9) using drift.
18 Install reverse gear needle bearing (8).
D26.50-1159-01
19 Install idler gear for reverse gear (7).
The collar must point upwards (towards the output end).
20 Install synchronizer ring (6).
The teeth must point downwards (towards the input end).
D26.50-1178-01
New synchronizer units are supplied already assembled.
Only if necessary:
21 Assemble new synchronizer unit:
21.1 Push sliding sleeve (1) onto reverse gear synchronizer body (2).
The closed side of the grooves in the reverse gear synchronizer body (2) must face downwards.
Push on the sliding sleeve (1) with the tapered sides of the tooth flanks pointing upwards, so that the balls (5) will subsequently engage in the center groove in the sliding sleeve teeth (arrow).
21.2 Install narrow sliders (4), compression springs (3) and balls (5) in reverse gear synchronizer body (2).
D26.50-1144-01
D26.50-1158-01
22 Install new reverse gear synchronizer assembly (50) and press on using sleeve.
The recesses in the synchronizer ring must engage in the grooves in the reverse gear synchronizer body.
D26.50-1199-01
23 Turn main shaft (27) over and clamp in vise with protective jaws.
Input end uppermost.
24 Install 6th gear needle bearing (28).
25 Install idler gear for 6th gear (29).
The straight teeth must point upwards (towards the input end).
D26.50-1200-01
26 Install clutch body (30).
The outer teeth must point downwards (towards the output end).
27 Install synchronizer ring (31).
The teeth must point downwards (towards the output end).
D26.50-1198-12
New synchronizer units are supplied already assembled.
Only if necessary:
28 Assemble new synchronizer unit:
28.1 Push sliding sleeve (36) onto 5th/6th gear synchronizer body (32).
When pushing on the sliding sleeve (36), align it to ensure that the balls (35) will subsequently engage in the center groove of the sliding sleeve teeth (arrow).
28.2 Install narrow sliders (34), compression springs (33) and balls (35) in 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)
D26.50-1201-01
29 Press on new 5th/6th gear synchronizer unit (52) using sleeve.
The inscription on the synchronizer body must face 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
30 Determine thickness of locking ring (39):
- Insert trial locking ring (thickness: 1.5 mm) using pliers and press all the way down (towards the output end).
- Measure distance between trial locking ring and top edge of groove in main shaft (27) using feeler gauge.
- Thickness of locking ring = measured value + 1.5 mm (trial locking ring).
- Remove trial locking ring using pliers.
31 Use pliers to install new locking ring (39) of the determined thickness
(increments: 0.05 mm).
Do not over-expand the locking ring. Ensure that the locking ring is properly seated.
D26.50-1202-01
32 Install synchronizer ring (37).
The drivers on the synchronizer ring (37) must engage in the grooves in the 5th/6th gear synchronizer body.
33 Install clutch body (38).
The outer teeth must point upwards (towards the input end).
34 Remove main shaft from vise.