ar2650d4775c

Countershaft, dismantling and assembly

Type ar · topic 26.50 · version 0104 · 2006-07-26

Applies to: TRANSMISSION 716.643 in MODEL 901.6, 902.6, 903.6, 904.6 TRANSMISSION 716.601 in MODEL 203.004, 210.007 TRANSMISSION 716.620 in MODEL 203.035, 210.035 /235 TRANSMISSION 716.621 in MODELS 210.061 /261 TRANSMISSION 716.622 in MODELS 170.444 /449, 203.045, 208.344 /444, 210.048 /248 TRANSMISSION 716.623 in MODEL 203.061, 209.361, 210.062 /063 /262 /263 TRANSMISSION 716.640 in MODEL 203.006, 210.006 /206 TRANSMISSION 716.641 in MODEL 203.016, 210.016 /216 TRANSMISSION 716.660 in MODELS 170.465 TRANS

Where it sits

Function group 2 Chassis › 26 Manual transmission › 26.50 Gear assembly, shafts, differential — Series 163 (models 113) · Series 170 (models 444, 449, 465) · Series 203 (models 004, 006, 016, 035, 045, 061) · Series 208 (models 344, 348, 444, 448) · Series 209 (models 342, 361) · Series 210 (models 006, 007, 016, 035, 048, 061, 062, 063, 206, 216, 235, 248, 261, 262, 263) · Series 901 (models 6**) · Series 902 (models 6**) · Series 903 (models 6**) · Series 904 (models 6**)

EinPAS 17 Drivetrain/axle › 17.20 Transmission › 17.20.50 Shaft/gear/synchronization — Series 163 (models 113) · Series 170 (models 444, 449, 465) · Series 203 (models 004, 006, 016, 035, 045, 061) · Series 208 (models 344, 348, 444, 448) · Series 209 (models 342, 361) · Series 210 (models 006, 007, 016, 035, 048, 061, 062, 063, 206, 216, 235, 248, 261, 262, 263) · Series 901 (models 6**) · Series 902 (models 6**) · Series 903 (models 6**) · Series 904 (models 6**)

Also applies to engines/gearboxes: 716 601, 716 620, 716 621, 716 622, 716 623, 716 628, 716 640, 716 641, 716 643, 716 644, 716 660, 716 662, 716 663

AR26.50-D-4775C

Countershaft, dismantling and assembly

8.6.99

TRANSMISSION 716.643 in MODEL 901.6, 902.6, 903.6, 904.6

TRANSMISSION 716.601 in MODEL 203.004, 210.007

TRANSMISSION 716.620 in MODEL 203.035, 210.035 /235

TRANSMISSION 716.621 in MODELS 210.061 /261

TRANSMISSION 716.622 in MODELS 170.444 /449, 203.045, 208.344 /444, 210.048 /248

TRANSMISSION 716.623 in MODEL 203.061, 209.361, 210.062 /063 /262 /263

TRANSMISSION 716.640 in MODEL 203.006, 210.006 /206

TRANSMISSION 716.641 in MODEL 203.016, 210.016 /216

TRANSMISSION 716.660 in MODELS 170.465

TRANSMISSION 716.644 in MODELS 163.113

TRANSMISSION 716.663 in MODELS 208.348 /448

TRANSMISSION 716.622 in MODEL 208.344 /444 with CODE (424) Sequentronic (SEQ) manual transmission

TRANSMISSION 716.662 in MODEL 208.348 /448 with CODE (424) Sequentronic (SEQ) manual transmission

TRANSMISSION 716.628 in MODELS 209.342

Countershaft, dismantling and assembly

D26.50-1180-09

1 Circlip

2 Constant-mesh gear

3 6th gear drive gear

4 3rd gear idler gear

5 3rd gear needle bearing

6 Clutch body

7 Friction ring

8 Synchronizer cone ring

17 Synchronizer ring

18 Synchronizer cone ring

19 Friction ring

20 Clutch body

21 4th gear idler gear

22 4th gear needle bearing

23 Countershaft

9 Synchronizer ring

10 Blocking piece

11 Sliding sleeve

12 Circlip

13 Compression spring

14 Sliding block

15 Ball bearing

16 3rd/4th gear synchronizer body

Disassemble

1

Disassemble transmission casing

Transmission 716.643 (van)

AR26.40-D-2002B

Transmission 716.6 (passenger car) except code 424

AR26.40-P-2002C

Transmission 716.6 (passenger car) with code 424

AR26.40-P-2002E

2

Disassembling countershaft

Never mix clutch bodies and sliders from different assemblies. Note correlation and installation position carefully to avoid mixing up.

AR26.50-D-4775-02A

Puller

*000589653300

Jaw

*000589873300

Pliers for external circlip

*WH58.30-Z-1008-02A

Inspect

3

Check all parts for damage and wear

Assemble

4

Oil all parts prior to installation

5

Assemble countershaft

Never mix clutch bodies and sliders from different assemblies. Note correlation and installation position carefully to avoid mixing up.

Replace circlips and synchronizer assemblies.

AR26.50-D-4775-03A

Sleeve

*716589023300

Sleeve

*168589001400

Pliers for external circlip

*WH58.30-Z-1008-02A

Feeler gauge

*WH58.30-Z-1004-12A

6

Assemble transmission housing

Transmission 716.643 (van)

AR26.40-D-2002B

Transmission 716.6 (passenger car) except code 424

AR26.40-P-2002C

Transmission 716.6 (passenger car) with code 424

AR26.40-P-2002E

Countershaft, dismantling and assembly
Countershaft, dismantling and assembly
Countershaft, dismantling and assembly
Countershaft, dismantling and assembly

000 589 87 33 00

Sleeve

Jaw

Puller

Sleeve

000 589 65 33 00

716 589 02 33 00

168 589 00 14 00

Commercially available tools

Number

Designation

WH58.30-Z-1008-02A

Circlip pliers for external circlip

WH58.30-Z-1004-12A

Feeler gauge

Referenced documents