Dismantle, assemble drive shaft.

AR26.50-S-4744A

Dismantle, assemble drive shaft.

27.2.12



Disassemble



A press with at least 25t is required for the operations described below.

Workshop press

gotis://G_58.2_01.0

1

Disassemble transmission

AR26.10-S-0001A

2

Unscrew clamping bolt (2).

3

Place removal plate (19) between synchronizer ring (8) and gearwheel (12)

Removal plate

4

Insert thrust piece and press off ball bearing (3), shift mechanism (5) and gearwheels (12, 9)

 The bushing (7) and needle roller bearing (6) for 4th and 5th gear are paired with each other. Do not mix up parts with each other. Do not mix up the shims (4) with the shims of the output shaft.

 Thrust piece

*638589013500

5

Remove ball (11)

6

Disassemble shift mechanism (5)

AR26.50-S-4744-03A

7

Press off bushing (7), shift mechanism (13) and gearwheel (17)

 The bushing (7) and needle roller bearing (6) for 4th and 5th gear are paired with each other. Do not mix up parts with each other.

 Thrust sleeve

*638589003500



Removal plate

WF58.50-N-2650-02A

8

Remove roller bearing (16) and thrust bearing (15)

9

Disassemble shift mechanism (13)

AR26.50-S-4744-02A



Checking

10

Check wear of synchronizer rings (8)

 Install new synchronizer rings (8) if necessary.

AR26.50-S-0420-13A

*BE26.50-N-1001-01E

Removal plate



Assemble



Apply a thin coating of transmission oil to all bearings before installation

11

Insert thrust bearing (15)

 In their original condition, the thrust bearing (15) on the 2nd gear fixed gear is black and the thrust bearing on the shift mechanism (13) is green.

If new thrust bearings (15) are installed, both are green.

12

Insert both roller bearings (16) and gearwheel (17)

13

Insert synchronizer ring (8)

14

Insert thrust bearing (15)

 In their original condition, the thrust bearing (15) on the 2nd gear fixed gear is black and the thrust bearing on the shift mechanism (13) is green.

If new thrust bearings (15) are installed, both are green.

15

Coat thrust plate (14) with transmission oil and place it on synchronizer body of shift mechanism (13)

16

Insert synchronizer body of shift mechanism (13) with larger collar pointing upwards and press on

 The guides of the synchronizer ring (8) must engage in the cutouts of the synchronizer body. When pressing on, lift the gearwheel (17) into the centering elements in the synchronizer body in order to fix the thrust plate (14) and the thrust bearing (15) in position.

 Fixture

*638589003100

 Press-in sleeve

*638589063500

17

Assemble shift mechanism (13)

AR26.50-S-4744-02A

18

Insert synchronizer ring (8)

 The guides of the synchronizer ring (8) must engage in the cutouts of the synchronizer body.

19

Press on bushing (7) as far as axial stop and insert needle roller bearing (6)

 The bushing (7) and needle roller bearing (6) for 4th and 5th gear are paired with each other. Do not mix up parts with each other.

 Fixture

*638589003100

 Press-in sleeve

*638589073500

20

Insert gearwheel (12)

21

Insert ball (11) and thrust plate (10)

22

Press on bushing (7) as far as axial stop and insert needle roller bearing (6)

 The bushing (7) and needle roller bearing (6) for 4th and 5th gear are paired with each other. Do not mix up parts with each other.

 Fixture

*638589003100

 Press-in sleeve

*638589073500

23

Insert gearwheel (9)

24

Insert synchronizer ring (8)

25

Insert synchronizer body of shift mechanism (5) and press on with groove for retaining ring facing upwards

 The guides of the synchronizer ring (8) must engage in the cutouts of the synchronizer body.

 Fixture

*638589003100

 Press-in sleeve

*638589073500

26

Assemble shift mechanism (5)

AR26.50-S-4744-03A

27

Insert removed shims (4)

 Do not mix up the shims (4) with the shims of the output shaft.

28

Press on ball bearing (3) with groove pointing upwards

 Fixture

*638589003100

29

Screw in rigging screw (2)

 Coat the thread of the rigging screw (2) with thread locking compound.

 Engine 111

*BA26.50-N-1002-01E

 Engine 601

*BA26.50-N-1002-01G

Loctite 243

*BR00.45-Z-1133-02A

30

Assemble transmission

AR26.10-S-0001A

Number

Designation

Model
638

BE26.50-N-1001-01E

Wear limit between synchronizer ring and gearwheel

mm

0.8

Number

Designation

Model 638 with engine 111.948/978
without Code G40

BA26.50-N-1002-01E

Rigging screw to drive shaft

Nm

95

Number

Designation

Model 638 with engine 601.942/970
without Code G40

BA26.50-N-1002-01G

Rigging screw to drive shaft

Nm

95

Number

Designation

Order number

BR00.45-Z-1133-02A

Loctite 243

A 613 989 09 71