Remove/install shift rails

AR26.60-D-2002A

Remove/install shift rails

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

Measure reference dimension "A" from countershaft to sealing surface of transmission cover and note

Depth gage

4

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

5

Remove needle roller bearing (18).

6

Remove cylindrical roller bearing (10)

Transmission 711.603

 Pay attention to position of roller cage.

7

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



Assemble



If the main shaft bearing is replaced, the main shaft bearing play must be adjusted

8

Adjust main shaft bearing play

AR26.50-D-2001-01A

Main shaft bearing axial play

*BE26.50-N-1001-01D

Feeler gauge

9

Assemble shift rails

 The cutouts (arrow) must align.



Reinforced shift rail bearing pins

BT26.60-D-0002-01A



Modified shift rail guide

BT26.60-D-0004-01A

10

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

*711589036300

 Centering device

*711589026300

 Press-in tool

*711589004300

 Synchronizer ring holder

*711589006300

11

Measure reference dimension "A" from countershaft to sealing surface of transmission cover

 If the reference dimension deviates from the reference dimension measured under operation step 3, adjust countershaft bearing play, see 

12.1

Adjust axial play of countershaft

Transmission 711.603

AR26.50-D-2001-02A

Countershaft axial play

*BE26.50-N-1002-01D

Depth gage

13

Insert cylindrical roller bearing (10)

Transmission 711.603

 Pay attention to position of roller cage.

 Grease cylindrical roller bearing.

14

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

15

Insert needle bearing

 Grease needle roller bearing.

16

Assemble transmission housing

AR26.40-D-2002A

17.1

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

18

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

Transmission
711.612/613

BA26.40-N-1005-01A

Bolt, bearing cap to transmission housing

Nm

21

Number

Designation

Trans-mission
711.603/
612/613

BA26.50-N-1001-01D

Nut, output flange to main shaft

M121.5

Nm

110

M241.5

Stage 1

Nm

-

Stage 2

Nm

-

Stage 3

Nm

-

M261.5

Stage 1

Nm

-

Stage 2

Nm

-

Stage 3

Nm

-

Number

Designation

Order number

BR00.45-Z-1012-01A

Sealant, Omnifit FD 3041

A 002 989 47 20 10