Disassemble, assemble transmission

AR26.10-S-0001B

Disassemble, assemble transmission

27.2.12

 

Disassemble/assemble

1

Remove transmission

 With engine 111.948/978 and 601

AR26.10-S-0020A

With engine 611.980

AR26.10-S-0020B

2

Remove bearing of transmission mounting (10)

AR26.10-S-0030A

3

Remove left drive flange (1)

AR33.30-S-1000A

4

Remove clutch

 With engine 111 and 601

AR25.10-S-0050A

Remove clutch

With engine 611.980

AR25.10-S-0050B

5

Remove stop plug

 Engine 111

*BA26.40-N-1010-01I

 Engine 611

*BA26.40-N-1010-01J

6

Remove locking pins (2) for shift forks

 Replace locking pins (2).

7

Remove shift shaft (4)

AR26.60-S-6500A

8

Remove backup lamp switch (S19)

AR26.19-S-0200A

9

Remove bearing cap (5).

AR26.30-S-3200A

10

Undo bolt (8)

 Replace bolts (8).

 Engine 111

*BA26.50-N-1002-01E

 Engine 611

*BA26.50-N-1002-01G

 Engine 111

*BA26.50-N-1003-01G

 Engine 611

*BA26.50-N-1003-01E

11

Unscrew screws (7)

 Engine 111

*BA26.40-N-1007-01I

 Engine 611

*BA26.40-N-1007-01J

 Torx bit set

*000589011000

12

Detach transmission housing (16)

 Coat sealing surfaces with sealing compound.

 Assembly: Detach transmission housing from drive shaft and output shaft using a shop-fabricated tool.

 Thrust piece

*638589013500

Removal plate (shaft)

WF58.50-N-2650-02A

Removal plate (output shaft)

WF58.50-N-2650-03A

Sealant

*BR00.45-Z-1009-01A

13

Remove drive shaft (12) and output shaft (11) with shift forks (13, 14 and 15) together from clutch housing (16)

14

Detach shift forks (13, 14 and 15) from drive shaft (12) and output shaft (11)

 Note installation position of shift forks (13, 14 and 15).

15

Check axial play of gearwheels

The axial play is a typical value and cannot be adjusted.

AR26.50-S-0420-16A

16

Disassemble input shaft (12)

AR26.50-S-4744B

17

Disassemble output shaft (11)

AR26.50-S-0419B

18

Check condition of teeth and bearings of gearwheels

19

Remove axle differential (17) from clutch housing (16)

20

Disassemble axle differential (17)

AR26.50-S-5000A

21

Remove shift fork (20)

22

Remove reverse gear shaft (18)

 Heat up housing to approx. 80-100 °C.

23

Check condition of teeth and bearings of reverse gear shaft (18)

24

Disassemble reverse gear shaft (18)

AR26.50-S-4800B

25

Check condition of bearing in clutch housing (19), disassemble clutch housing (19) if necessary

AR26.40-S-2472B

26

Check condition of bearing in transmission housing (16), disassemble transmission housing (16) if necessary

AR26.40-S-2002B

27

Assemble in the reverse order

Number

Designation

Model 638 with engine 111.948/978 without Code G40

BA26.40-N-1007-01I

Transmission housing to clutch housing

Nm

23

BA26.40-N-1010-01I

Bolt, closure plugs to transmission housing

Nm

-

Number

Designation

Model 638 with engine 611.980
without Code G40

BA26.40-N-1007-01J

Transmission housing to clutch housing

Nm

25

BA26.40-N-1010-01J

Bolt, closure plugs to transmission housing

Nm

7

Number

Designation

Model 638 with engine 111.950/980 code G40

BA26.50-N-1002-01E

Rigging screw to drive shaft

Nm

95

BA26.50-N-1003-01E

Clamping screw to output shaft

Nm

95

Number

Designation

Model 638 with engine 611.980 without code G40

BA26.50-N-1002-01G

Rigging screw to drive shaft

Nm

95

BA26.50-N-1003-01G

Clamping screw to output shaft

Nm

95

Number

Designation

Order number

BR00.45-Z-1009-01A

Sealing compound Loctite 574, 50 ml

A 001 989 89 20 10

BR00.45-Z-1133-02A

Loctite 243

A 613 989 09 71