Replace the bushings of the top shift by cables

AR26.60-B-0701B

Replace the bushings of the top shift by cables

12.02.16



Important preliminary measures

1

Park the vehicle on a flat and level location that presents safety and chock the wheels to avoid its unintentional displacement

2

Disconnect the battery negative cable or turn-off the master switch

 On vehicles fitted with electronic engine management, always follow the recommendations referring to the care with the vehicle's electronic part.

3

Remove the shifter bellows boot from inside the cab

 Carry out this operation before tilting the cab.

4

Take the necessary safety measures to tilt the cab

AS60.80-B-0001-01A

5

Tilting the cab

AR60.80-B-0010A



Remove

6

On the top shift, lock in neutral (gearbox neutral) the selection (14) and shift (15) levers with the screw (13). The same will have to be screwed through the orifice existing on the shifter

 The screw will have to be fully screwed in, so the assembly of the top shift of which the shifter is part remains locked in neutral.

*BE26.60-B-1001-01G

7

Loosen the ball terminals (16) of the selection (14) and shifting (15) levers

8

Remove the two bolts (19) and loosen the support of the clamps of the main bracket (20)

9

Remove the bolts (1) attaching the main bracket (20) on the cab floorboard and remove the complete shift

 The nuts are fastened on the floorboard from the cab inside.



Disassembling

10

Secure the shift support in a vise with the jaws protected and remove all the locking elastic rings (6), (8) and (11)

 Utilize a bronze or copper dowel to remove the shafts.

11

Remove the selection shaft (5) and separate the shifter (2) from the universal joint

 Utilize a bronze or copper dowel to remove the shafts.

 To facilitate the job, utilize a workshop press and appropriate support to remove the shafts.

12

Remove the locking screw (13), the slotted pin (17). From the bottom part of the universal joint (12) remove, the slotted pin (17) and the selection lever (14) together with the guide pin (18)

 Be careful in order not to damage the selection and shifting levers.

13

Remove the shift shaft (7) pressed in the main bracket (20) and lift off the universal joint (4).

 Utilize an appropriate support and a workshop press.

14

Remove from the universal joint (4), the bushings (7.1) and (9) and also from the selection lever the bushing (10)

 Provide for a tube with a lightly smaller diameter than the bushings and utilize a workshop press. The diameter of the new bushings of the repair kit may be taken as reference.



Clean

15

Clean all components and remove any sharp edge that may damage the new bushings or make their assembly difficult

 In the case of re-utilizing the selection (5) and shifting (7) shafts, it is necessary to throughly remove any residue of chemical lock of the shafts fitting parts on the main bracket (20) and on the fittings of the fork (3) integrated on the shifter (2).



Checking

16

Check all components and replace those presenting wear. Replace all locking elastic rings of the shafts

Attention!: The following parts are supplied as repair: Kit of the shifter parts (2) and (3). Kit of the universal joint with the selection levers, parts (4), (14), (15), (17) and (18). Kit of sliding bushings, parts (7.1), (9) and (10). Kit of the shift shaft, part (7).



Assembling

17

Assemble the new sliding bushings (7.1) on the integrated fork (3) of the shifter (2), the sliding bushings (9) on the universal joint and the bushing (10) on the selection lever (14)

 To facilitate the assembly on the workshop press of the sliding bushings (1), (9) and (10) a thin layer of petroleum jelly may be applied on the seating areas.

*BR00.45-B-1001-06A

18

Lubricate the inside of the sliding bushings, being one in each assembly operation of the respective shafts

 Utilize specified grease only on the sliding bushings. The fittings of the shafts on the fork (3) and on the bracket (20) must not receive lubrication.

*BR00.45-B-1003-06A

19

Assemble the fork (3) with the integrated shifter (2) on the universal joint (4) and insert the selection shaft (5). At the final fitting of the fork (3) apply a layer of chemical lock

 After centering the selection shaft install the new elastic locking rings (16).

*BR00.45-B-1007-02A

20

Assemble the universal joint (4) on the main bracket (20) and insert the shift shaft (7) in the universal joint and on the bracket. At the final fitting of the shaft (7) on the main bracket (20). apply a layer of chemical lock

 Once the shaft is centered, install the new elastic locking rings (8).

*BR00.45-B-1007-02A

21

Assemble on the bottom part of the universal joint (12) the selection lever (14) with the threaded guide pin (18)



*BA26.60-B-1007-01H

 Lubricate the sliding parts with specified grease.

*BR00.45-B-1003-06A

22

Install in the universal joint the shifting lever (15) and the slotted pin (17)

 Install a new elastic ring (11) in the bottom part of the universal joint (12) and check the its sliding on the levers.

23

Assemble on the floorboard the main bracket (20) with the shift and tighten the bolts (1)

 The nuts are fastened on the floorboard from inside the cab.

*BA26.60-B-1006-01H

24

Fasten the support of the clamps on the main bracket (20) tightening the bolts (19)



*BA26.60-B-1003-01H

25

Install the bolt (13) and lock the shift in neutral

 Should it be necessary, adjust or replace the actuation cables, carry out the operations.

AR26.60-B-6626A

AR26.60-B-6635A

26

Tighten the cable ball terminals (16) on the respective selection (14) and shifting (15) levers



*BA26.60-B-1002-01H

 If applying chemical lock, confirm the cleanliness of the threads before the application and tightening.

 The cables must not be forced nor twisted.

*BR00.45-B-1007-02A

27

Return the cab and install the shifter bellows boot on the floorboard from inside the cab

AR60.80-B-0010A

28

Remove the neutral locking bolt (13). Fasten the cab definitely and check the operation of the shift

29

Connect the battery negative cable or turn-on the master switch

 On vehicles fitted with electronic engine management, always follow the recommendations referring to the care with the vehicle's electronic part.

30

Do a test-drive

 Check the behavior of the gear shifting system.

Número

Denominação

Chassis 693.023/081 with 713.756/757 gearbox

Chassis 693.108/127/128, 693.144/181/183, 693.190/191/195 with gearbox 712.440/441 and 718.733/790

BE26.60-B-1001-01G

Measurement of the bolt locking the shift lever in neutral on the floorboard shift

mm

M5x1.5x30

M5x1.5x30

Número

Denominação

Gearboxes 713.756/757

Gearboxes 712.440/441/443, 712.641, 718.733/790

BA26.60-B-1002-01H

Ball joint terminals on selection and shift levers

Nm

16...23

16...23

BA26.60-B-1003-01H

Support screw

Nm

15...20

15...20

BA26.60-B-1006-01H

Bolts of the shift main support on cab flooring

Nm

15...20

15...20

BA26.60-B-1007-01H

Guide pin on the selection lever on the top shift

Nm

35...40

35...40

Número

Denominação

Número de pedido

BR00.45-B-1007-02A

Chemical lock

Loctite 290

Número

Denominação

Número de pedido

BR00.45-B-1001-06A

Vaseline

-

BR00.45-B-1003-06A

Grease as per DBL 6804 - Class 267.0

-

BR00.45-B-1007-06A

Grease DBL 6812.00

Klueber Lubrification