Remove/install and adjusting main shaft and countershaft

AR26.50-D-2001A

Remove/install and adjusting main shaft and countershaft

11.11.11



Removing

1

Remove transmission

Transmission 711.603/ 612

AR26.10-D-0020B

Transmission 711.613

AR26.10-L-0020E



Disassemble

2

Disassemble transmission housing

AR26.40-D-2002A

3

Remove synchronizer cone (6) and synchronizer ring (7) of 4th gear.

 The synchronizer cone (6) and synchronizer ring (7) cannot always be removed.

4

Remove needle roller bearing (18).

5

Remove cylindrical roller bearing (10)

Only if transmission 711.603 is fitted

 Pay attention to position of roller cage.

6

Remove main shaft, shift rails and countershaft with collecting box

 On transmission 711.612 /613 remove collecting box inserts.

AR26.50-D-2002-03A



*711589016300

Adjust

7

Adjust main shaft bearing play

AR26.50-D-2001-01A

*BE26.50-N-1001-01D

Feeler gauge



Assemble

8

Put shift rails together

 The cutouts (arrow) must align.



Reinforced shift rail bearing pins

BT26.60-D-0002-01A



Modified shift rail guide

BT26.60-D-0004-01A

9

Install main shaft with shift rails and countershaft in rear section of transmission housing

 As of approx. 10/97 the bolt holes in the rear section of the transmission housing have been modified. To support the centering device the bore for supporting the offset parallel pin of the housing separation surface must be drilled out to a depth of 10 mm and a diameter of  9.6.

AR26.50-D-2002-02A

 Centering device, transmission 711.603

*711589026300

 Centering device, transmission 711.612 /613

*711589036300

 Synchronizer ring holder

*711589006300

 Press-in tool

*711589004300

10.1

Adjust axial play of countershaft

Transmission 711.603

AR26.50-D-2001-02A

Countershaft axial play

*BE26.50-N-1002-01D

Depth gage

11

Insert cylindrical roller bearing (10)

Transmission 711.603

 Pay attention to position of roller cage.

 Grease cylindrical roller bearing.

12

Insert synchronizer cone (6) and synchronizer ring (7) of 4th gear.

 Only if the synchronizer cone (6) and synchronizer ring (7) were removed.

13

Insert needle roller bearing (18)

 Coat needle bearing with long-term grease.

*BR00.45-Z-1001-06A

14

Assemble transmission housing

AR26.40-D-2002A

15.1

Adjust axial play of countershaft

Transmission 711.612 /613

AR26.50-D-2001-02B

Countershaft axial play

*BE26.50-N-1003-01D

 Bearing cap

*BA26.40-N-1005-01A

 Tensioning device

*711589023100

Depth gage

Omnifit FD 3041 sealant

*BR00.45-Z-1012-01A



Install

16

Install transmission

Transmission 711.603/ 612

AR26.10-D-0020B

Transmission 711.613

AR26.10-L-0020E

Number

Designation

Trans-mission 711.603

Transmission 711.612/613

BE26.50-N-1001-01D

Axial play between main shaft bearing and retaining ring

mm

0,02-0,08

0,02-0,08

BE26.50-N-1002-01D

Axial play between countershaft and retaining ring

mm

0,1-0,2

-

BE26.50-N-1003-01D

Axial play between countershaft and tensioning device

-

0 (-0.06/+0.02)

Number

Designation

Trans-mission
711.612/
613

BA26.40-N-1005-01A

Bolt, bearing cap to transmission housing

Nm

21

Number

Designation

Trans-mission 711.603

Trans-mission 711.612

Trans-mission 711.613

BA26.60-N-1003-01A

Bolt, shift rail guide plate to transmission housing

Nm

21

21

21

Number

Designation

Order number

BR00.45-Z-1012-01A

Sealant, Omnifit FD 3041

A 002 989 47 20 10

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11