Remove/install shift forks and shift rails

AR26.60-Y-0010A

02.01.2020

Transmission

400.712 in model 831.001/002/005

Remove/install shift forks and shift rails

Y26.60-0040-07

6th shift fork and rail jaw removal procedure

1	Spring pin		3	6th gearshift rail jaw
2	6th shift fork

4	Split pin
5	Lock nut
6	Shifting key retainer
7	6th gear synchronizer unit

Y26.60-0041-06

8	Alignment mark
9	Inner ring
10	Centering cone
11	Outer ring
12	Hub
13	Sleeve
14	Countershaft 6th gear

Y26.60-0042-06

Y26.60-0043-09

15	6th gear outer synchronizer ring	18	Distance piece
16	6th gear center synchronizer cone	19	6th gear (main shaft)
17	6th gear inner synchronizer ring	20	6th gear (Counter shaft)

Y26.60-0044-07

21	6th gear needle bearing		23	6th gear spacer sleeve
22	Rear bearing retainer

Y26.60-0045-09

24	Snap ring	27	Special tool bearing puller and installer (main shaft) 090 589 17 43 00
25	Special tool bearing puller and installer (Counter shaft) 090 589 16 43 00	28	Main shaft bearing
26	Counter shaft bearing	29	Reverse idler gear cover

Y26.60-0046-07

30	Special tool impact extractor 355 589 01 63 00	33	Thrust washer
31	Reverse idler gear shaft puller adaptor 090 589 35 33 00	34	1st and reverse gear lever pivot bolts
32	Reverse idler gear

Y26.60-0047-09

35	Detent ball retaining plate	39	Gear selector lever case
36	Poppet spring	40	Stopper plate
37	Detent balls	41	Interlock pad
38	Breather

Y26.60-0048-07

42	Transmission case mounting bolts		44	6th gearshift rail
43	Transmission case		45	Bearing retaining plate mounting bolt

46	Special tool holder main and counter shaft 090 589 08 40 00
47	Special tool hook 090 589 15 62 00
48	Main shaft unit
49	Bearing retainer plate
50	Shift unit
51	Counter shaft

Y26.60-0049-06

Shift rails dismantling and assembly procedure

60	1st and reverse gear shift rail jaws
61	2nd and 3rd shift rail jaw
62	Shift fork
63	4th and 5th shift rail jaw
64	6th gearshift rail jaw

Y26.60-0061-06

6th shift fork and rail jaw installation procedure

46	Special tool holder main and counter shaft 090 589 08 40 00
47	Special tool hook 090 589 15 62 00
48	Main shaft unit

Y26.60-0050-04

Y26.60-0051-09

42	Transmission case mounting bolts	49	Bearing retainer plate
43	Transmission case	52	Shift fork unit (1st and reverse)
44	6th gearshift rail	53	Shift fork unit (2nd and 3rd)
45	Bearing retaining plate mounting bolt	54	Shift fork unit (4th and 5th)
46	Special tool holder main and counter shaft 090 589 08 40 00

Y26.60-0052-07

24	Snap ring	27	Special tool bearing puller and installer (main shaft) 090 589 17 43 00
25	Special tool bearing puller and installer (Counter shaft) 090 589 16 43 00	28	Main shaft bearing
26	Counter shaft bearing	34	1st and reverse gear lever pivot bolts

Y26.60-0053-09

13	Sleeve	55	Rear retaining plate
29	Reverse idler gear cover	56	Reverse idler shaft
32	Reverse idler gear	57	Spacer
33	Thrust washer

Y26.60-0054-07

17	6th gear inner synchronizer ring		21	6th gear needle bearing
20	6th gear (Counter shaft)

Y26.60-0055-09

6	Shifting key retainer	16	6th gear center synchronizer cone
7	6th gear synchronizer unit	18	Distance piece
15	6th gear outer synchronizer ring	19	6th gear (main shaft)

Y26.60-0056-07

3	6th gearshift rail jaw		5	Lock nut
4	Split pin		58	Special tool retainer wrench 717 589 00 31 00

1	Spring pin
2	6th shift fork

Y26.60-0057-04

	Remove
1	Remove rear extension housing.		AR26.40-Y-2477B
2	Remove the spring pin (1) from 6th gearshift rail jaw.	 Use special tool cotter pin remover and hammer.
		 Punch-out drift	*090589126300
3	Remove the 6th shift fork (2) from shift rail.
4	Remove the 6th gearshift rail jaw (3).
5	Remove the split pin (4) from 6th gear synchronizer unit.
6	Remove the lock nut (5) from 6th gear synchronizer unit.
7	Remove the shifting key retainer (6) from 6th gear synchronizer unit.
 Warning	Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension	Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.	AS00.00-Z-0001-01A
8	Remove the 6th gear synchronizer unit (7).	 Take care when pulling the sliding sleeve off the gear synchronizer hub. The all keys spring loaded.
9	Make alignment marks (8) on synchronizer hub (12) and counter shaft 6th gear (14), at one location before disassembly.	 Make alignment marks on synchronizer inner ring (9), centering cone (10), outer ring (11) and sleeve (13), every at one location aligning with the alignment mark made on synchronizer hub before disassembly.
10	Remove the mentioned 6th gear components.	 6th gear outer synchronizer ring (15). 6th gear center synchronizer cone (16). 6th gear inner synchronizer ring (17).
11	Remove distance piece (18) from main shaft.
12	Remove the 6th gear from main shaft (19) and counter shaft (20).
13	Remove 6th gear needle bearing (21) from counter shaft.
14	Remove the rear bearing retainer (22) mounting bolts from transmission case.
15	Install plate type puller on 6th gear spacer sleeve (23) from counter shaft using plate type puller.
16	Remove snap ring (24) from main shaft and counter shaft.
17	Install the special tool bearing puller and installer (25) on counter shaft bearing.	 Tighten the special tool bearing puller and installer centering pin and detach the counter shaft bearing (26).
		 Removal and insertion device	*090589164300
18	Install the special tool bearing puller and installer (27) on main shaft bearing.	 Tighten the special tool bearing puller and installer centering pin and detach the main shaft bearing (28).
		 Extraction and insertion tool	*090589174300
19	Remove the reverse idler gear cover (29) mounting bolts from transmission case.	 Be careful not to pry the scraper halfway. This is deform the reverse idler gear cover or damage the transmission case.
20	Remove reverse idler gear shaft from transmission case.	 Use special tool impact extractor (30) and reverse idler gear shaft puller adaptor (31).
		 Impact extractor	*355589016300
		 Puller	*090589353300
21	Inspect the play of reverse idler gear.
22	Remove the reverse idler gear (32) along with 2 pieces thrust washer (33).
23	Remove 1st and reverse gear lever pivot bolts (34) on both the sides from transmission case.
 Warning	Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension	Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.	AS00.00-Z-0001-01A
24	Remove the detent ball retaining plate (35) mounting bolts from the transmission case.	 Care to be taken while removal of detent ball retaining plate. This must spring loaded.
25	Remove the poppet spring (36) and detent balls (37) using magnetic strip.
26	Remove the breather (38) from gear selector lever.
27	Remove the gear selector lever case (39) mounting bolts from transmission case.	 Be cautious while removing. Failure to comply may damage the gear selector lever case.
28	Remove stopper plate (40) mounting bolts both sides from transmission case.
29	Remove the interlock pad (41).	 Rotate the fixture to vertical position.
30	Remove transmission case mounting bolts (42) from clutch housing.	 Use mallet hammer for removal of the transmission case (43).
31	Remove the 6th gearshift rail (44).
32	Remove the bearing retaining plate mounting bolt (45) from the clutch housing.
33	Clamp the main shaft and counter shaft.	 Use special tool holder main and counter shaft (46) at third gear.
		 Counterholder	*090589084000
34	Install the special tool hook (47) on main shaft unit (48).	 Lift the unit to the level of approach for removal of retaining plate. Slide and remove the retaining plate and take out the main shaft unit.
		 Hook	*090589156200
35	Remove the bearing retaining plate (49).
36	Place the main shaft unit (48) in bench and remove the special tool holder main and counter shaft (46).	 Counterholder	*090589084000
37	Remove the shift unit (50) together with main shaft unit and separate the counter shaft (51).
 	Disassemble/assemble
38	Remove 1st and reverse gear shift rail jaws (60) from the shift rail.	 Use special tool spring pin remover and hammer.
		 Punch-out drift	*090589126300
39	Remove 2nd and 3rd shift rail jaw (61) and shift fork (62) from the shift rail.	 Use special tool spring pin remover and hammer.
		 Assembly: Inspect shift rail for any bend.
		 Punch-out drift	*090589126300
40	Remove 4th and 5th shift rail jaw (63) and shift fork (62) from the shift rail.	 Use special tool spring pin remover and hammer.
		 Punch-out drift	*090589126300
41	Remove 6th gearshift rail jaw (64) from the shift rail.	 Use special tool spring pin remover and hammer.
		 Punch-out drift	*090589126300
42	Assemble in the reverse order.
	Install
43	Clamp the main shaft and counter shaft together using special tool holder main and counter shaft (46).	 Place the shift fork and shift rail on the main shaft.
		 Counterholder	*090589084000
44	Hold the main shaft unit (48) using special tool hook (47).	 Place the bearing retaining plate (49) on top of main shaft and countershaft bearings.
		 Hook	*090589156200
45	Insert the shaft unit in the housing.	 Remove the special tool holder main and counter shaft (46). Main and counter shaft bearings to be seated in the races of the clutch housing.
		 Counterholder	*090589084000
46	Fit the shift fork units 1st and reverse (52), 2nd and 3rd (53), 4th and 5th (54) to the sliding sleeve.
47	Install the bearing retaining plate mounting bolts (45) to the clutch housing.	 Bearing retainer plate to clutch housing	*BA26.60-Y-1004-01B
48	Install the 6th gearshift rail (44) to the clutch housing.
49	Install the transmission case (43) to clutch housing.	 Apply recommended sealant to the transmission case and clutch housing.
		ThreeBond 1215	*BR00.45-Z-1142-01A
50	Install the transmission case mounting bolts (42) to the clutch housing.	 Transmission case to clutch housing	*BA26.60-Y-1005-01B
51	Install 1st and reverse gear lever pivot bolts (34) to the transmission case.	 Apply recommended sealant to the lever pivot bolt threaded area.
		Auto Lock	*BR00.45-Z-1115-01A
		 1st and reverse gear lever pivot bolts to transmission case	*BA26.60-Y-1006-01B
52	Install the main shaft bearing (28) into the shaft, fit the snap ring (24) into the bearing.	 Fit the bearing using special tool bearing puller and installer (27).
		 Extraction and insertion tool	*090589174300
53	Install the counter shaft bearing (26) into the shaft, fit the snap ring (24) to the bearing.	 Fit the bearing using special tool bearing puller and installer (25).
54	Install the rear retaining plate (55) mounting bolts to transmission case.	 Rear retainer plate to transmission case	*BA26.60-Y-1007-01B
55	Install reverse idler gear (32) along with 2 piece thrust washer (33) in the transmission case.	 Ensure locking projection in the groove of the spacers faces transmission housing.
56	Install the reverse idler shaft (56) in the transmission case.
57	Install reverse idler gear cover (29) mounting bolts to the transmission case.	 Don't start the engine within one hour after installing the reverse idler gear cover. Failure to comply, damage the reverse idler gear cover.
		 Apply recommended sealant to the reverse idler cover evenly.
		 When loosening or removing reverse idler gear cover mounting bolts, be sure to re-apply per coating sealant.
		Loctite 5999	*BR00.45-Z-1145-01A
		 Reverse idler gear cover to transmission case	*BA26.60-Y-1008-01B
58	Install spacer (57) in the counter shaft.	 Spacer oil groove must face towards sleeve.
59	Install sleeve (13) in the counter shaft after heating the sleeve using induction heater.	Counter shaft sleeve installation (Heating temperature range)	*BE26.60-Y-1002-01A
60	Install the 6th gear needle roller bearing (21) to counter shaft.
61	Install the 6th gear (20) facing upwards to counter shaft.	 Place the synchronizer sleeve in neutral position before installing the 6th and reverse lever.
62	Install the mentioned 6th gear components.	 6th gear inner synchronizer ring (17). 6th gear center synchronizer cone (16). 6th gear outer synchronizer ring (15).
63	Install the 6th gear synchronizer unit (7).	 Synchronizer hub collar side to face the 6th gear. Place the synchronizer sleeve in neutral position before installing the 6th and reverse lever.
64	Install 6th gear (19) in the main shaft.	 Spline end inside the gear wheel to face the coupling flange.
65	Install the distance pieces (18) in the main shaft.
66	Install the shifting key retainer (6) to counter shaft.
67	Install 6th gear lock nut (5), assemble the coupling flange using special tool retainer wrench (58) to hold and tighten the lock nut.	 Remove the special tool and flange after installation.
		 Tighten the 6th gear lock nut	*BA26.60-Y-1009-01B
		 Retainer wrench	*717589003100
68	Install the split pin (4) to counter shaft.
69	Install the 6th gearshift rail jaw (3).
70	Install the 6th reverse lever and shift fork piece (2) to shift rail, 6th gear synchronizer sleeve.
71	Install the spring pin (1) to the 6th gearshift rail jaw.
72	Install rear extension housing.		AR26.40-Y-2477B

Gearshift linkages removal and refitment

Number	Designation		Transmission 400.712 in model 831.001/002/005
BE26.60-Y-1002-01A	Counter shaft sleeve installation (Heating temperature range)	°C	100-120