Remove/install shift rails · ar2660g2002a · Mercedes-Benz WIS

AR26.60-G-2002A

Remove/install shift rails

10.11.11

TRANSMISSION 711.612

D26.50-0088-09

1 Hexagon socket head screw

2 Cover

3 Front section of transmission housing

3.1 Adjusting disk

4 Reverse idler shaft bolt

5 Reverse idler shaft

6 Synchronizer cone

14 Shift rail lock bolts

16 Pulse generator

17 Hexagon bolt

18 Needle roller bearing

19 Setting rings (only with power takeoff)

7 Synchronizer ring

8 Main shaft

9 Countershaft

10 Tapered roller bearing

11 Tapered roller bearing

12 Shift rails

13 Rear section of transmission housing

	Removing
1	Remove transmission		AR26.10-G-0020B
	Disassemble
2	Disassemble transmission housing		AR26.40-G-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 tapered roller bearing (10)	 Remove collecting box inserts.
7	Remove main shaft, shift rails and countershaft with collecting box		AR26.50-G-2002-03A
		 Collecting box	*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-G-2001-01A
		Main shaft bearing axial play	*BE26.50-N-1001-01D
		Feeler gauge
9	Assemble shift rails	 The cutouts (arrow) must align.
10	Install main shaft with shift rails and countershaft in transmission cover	 As of approx. 10/97 the bolt holes in the rear section of the transmission housing have been modified. To locate the centering device the bore to locate the stepped parallel pin must be drilled to dia. 9.6 to a depth of 10mm starting from the housing separating surface.	AR26.50-G-2002-02A
		 Centering device	*711589036300
		 Centering device	*711589026300
		 Press-in tool	*711589004300
		 Synchronizer ring holder	*711589006300
11	Insert synchronizer cone (6) and synchronizer ring (7) of 4th gear.
12	Insert needle bearing	 Grease needle roller bearing.
13	Assemble transmission housing		AR26.40-G-2002A
14	Adjust axial play of countershaft		AR26.50-G-2001-02A
		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
15	Install transmission		AR26.10-G-0020B

Gear set adjustment values

Number	Designation		Transmission 711.612/613


BE26.50-N-1001-01D	Axial play between main shaft bearing and retaining ring	mm	0,02-0,08
BE26.50-N-1003-01D	Axial play between countershaft and tensioning device		0 (-0.06/+0.02)

 Transmission housing

Number	Designation		Transmission 711.612 / 613


BA26.40-N-1005-01A	Bolt, bearing cap to transmission housing	Nm	21

 Gear set, shafts

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	-

711 589 00 63 00

Collecting box

Synchronizer ring holder

Press-in tool

Tensioning device

711 589 00 43 00

711 589 01 63 00

711 589 02 31 00

711 589 03 63 00

Centering device

711 589 02 63 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1012-01A	Sealant, Omnifit FD 3041	A 002 989 47 20 10

Referenced documents

ar2610g0020b Remove/install transmission
ar2640g2002a Disassemble/assemble transmission housing
ar2650g200101a Adjusting main shaft bearing play
ar2650g200102a Adjust axial play of countershaft
ar2650g200202a Install main shaft with shift rails and countershaft in rear section of transmission housing
ar2650g200203a Removing main shift, shift rails and countershaft