Dismantle, assemble drive shaft.

AR26.50-P-4744FF

Dismantle, assemble drive shaft.

11.11.11



Disassemble

1

Remove drive shaft (1) from rear section of transmission housing

AR26.40-P-2476FF

2

Detach sliding sleeve (3) upwards from the synchronizer body (2) and remove the three 180° offset thrust pieces (5)

 Observe installation position of sliding sleeve (3).

The sliding sleeve (3) has three 180° offset grooves (arrow a) into which the thrust piece balls (5) mesh. There are also several large, 180° offset teeth (arrow b) on the sliding sleeve (3) which can only be positioned into the corresponding cutouts. These special features help to define the exact installation position of the sliding sleeve (3).

3

Mount puller (7) with flat side facing upwards, as shown in picture A, and position drive shaft (1) in hydraulic press (6)

 Position puller (7) between gear wheel for 4th. gear (9) and gear wheel for 3rd. gear (12) (arrow c).



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Workshop press

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4

Use heat gun (14) to heat up synchronizer body (2) as well as gear wheel for 4th. gear (9) and press down using the hydraulic press (6)

 Hold drive shaft (1) firmly during the removal procedure, to ensure that it does not fall down and suffer damage.

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gotis://K_60-65_11.0

5

Remove drive shaft (1) from hydraulic press (6) and remove synchronizer body (2), synchronizer ring (10), needle bearing (11), idler gear for 5th. gear (8) and gear wheel for 4th. gear (9)

6

Screw on puller (7) with flat side facing upwards, as shown in picture B, and position drive shaft (1) in hydraulic press (6)

 Position puller (7) below gear wheel for 3rd. gear (12).



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7

Use heat gun (14) to heat up gear wheel for 3rd gear (12) and press down using the hydraulic press (6).

 Hold drive shaft (1) firmly during the removal procedure, to ensure that it does not fall down and suffer damage.

8

Remove drive shaft (1) from hydraulic press (6) and remove gear wheel for 3rd. gear (12)



Checking

9

Check all parts of input shaft (1) for damage and wear

 If gear wheels are damaged or broken the gear wheels that they mesh with must also be replaced.

See: 

Disassembling and assembling output shaft

AR26.50-P-0419FF



Assemble

10

Clean all parts before installation and coat with transmission oil

11

Position gear wheel for 3rd. gear (12) and gear wheel for 4th gear (9) on the drive shaft (1)

 Observe installation position of gear wheel of 3rd. gear (12) and gear wheel of 4th gear (9).

12

Position drive shaft (1) with gear wheel for 3rd. gear (12) and gear wheel for 4th. gear (9) on a suitable sleeve (13), as shown in picture C, in the hydraulic press (6)

13

Use heat gun (14) to heat gear wheel for 3rd. gear (12) and gear wheel for 4th gear (9) and use hydraulic press (6) to press all the way on

14

Position needle bearing (11) and idler gear for 5th gear (8) onto drive shaft (1)

15

Position synchronizer ring (10) and synchronizer body (2) onto drive shaft (1)

16

Position drive shaft (1), as shown in picture D, into the hydraulic press (6)

17

Use heat gun (14) to heat synchronizer body (2) and then use hydraulic press (6) to press all the way on

18

Insert the three 180° offset thrust pieces (5) into the synchronizer body (2)

19

Align sliding sleeve (3) to match the grooves (arrow a) and the large teeth (arrow b), and slide over the synchronizer body (2)

 The sliding sleeve (3) has three 180° offset grooves (arrow a) into which the thrust piece balls (5) mesh. There are also several large, 180° offset teeth (arrow b) on the sliding sleeve (3) which can only be positioned into the corresponding cutouts. These special features help to define the exact installation position of the sliding sleeve (3).

20

Install sleeve (4)

21

Insert drive shaft (1) into the rear section of the transmission housing and assemble the rear section of the transmission housing

AR26.40-P-2476FF