Gear set adjustment values
Number | Designation | Transmission | ||
BE26.50-N-1007-01D | Protrusion, measuring drift for determining the package dimensions | "A" | mm | 39,97 to 40,03 |
711 589 00 15 00
Set of assembly clamps
Feeler
Drift
Drift
198 589 03 39 00
711 589 01 37 00
711 589 07 15 00
716 589 02 33 00
Sleeve
Drift
711 589 17 15 00
D26.50-1245-01
For installing the synchronizer units the respective seat on the main shaft and contact surfaces of the synchronizer units must be grease-free.
A workshop press is required for pressing on the synchronizer units. The required press force is approx. 3 t.
Oil friction rings, cone rings, synchronizer rings and needle bearings lightly with automatic transmission fluid before installing.
1 Attach main shaft, drive side upwards, with the fixed gear of 3rd gear (31) to the workshop press mount.
2 Install oil baffle (22) and needle bearing of 6th gear (23).
3 Install clutch body (25) with synchronizer ring (26) on the idler gear of 6th gear (24) and attach synchronizer unit of 5th/6th gear (27) to synchronizer ring (26).
The inscription on the synchronizer unit of 5th/6th gear (27) must point towards the drive side. The drivers of the synchronizer ring (26) must engage in the grooves of the synchronizer unit of 5th/6th gear (27).
4 Press on synchronizer unit of 5th/6th gear (27), synchronizer ring (26), clutch body (25) and
idler gear of 6th gear (24) as far as the end stop using drift (198 589 03 39 00).
5 Install new circlip (30).
D26.50-1246-03
D26.50-1241-01
6 Determine thickness of thrust plate (6):
- Install synchronizer unit of 1st/2nd gear (13), bearing bushing of 1st gear (9), thrust plate (6), bearing bushing of reverse gear (5) and synchronizer unit of reverse gear (1) on measuring drift (57).
- Measure protrusion (A) of measuring drift (57) and select corresponding thrust plate.
The specified dimension of the protrusion (A) must be adhered to exactly. Thrust plates (6) are available with a thickness of 5.70 up to 6.15 mm and a graduation of
0.05 mm.
- Detach components from measuring drift (57).
D26.50-1242-01
7 Attach main shaft, output side upwards, with the fixed gear of 4th gear (32) to the workshop press mount.
8 Install the roller bearing intermediate plate (20) with the inscription towards the output side.
9 Press on new thrust plate (19) with drift (711 589 17 15 00).
The thrust plate (19) must always be replaced. The chamfered side of the thrust plate (19) must point towards the roller bearing intermediate plate (20) .
10 Install needle bearing of 2nd gear (18).
D26.50-1236-02
11 Install friction ring (16) and cone ring (15).
The cam of the friction ring (16) must point towards the output side. The cams of the cone ring (15) must engage in the cutouts of the idler gear of 2nd gear (17).
12 Install synchronizer ring (14).
The toothing on the synchronizer ring (14) must point towards the idler gear of 2nd gear (17). The cams of the friction ring (16) must engage in the cutouts of the synchronizer ring (14).
13 Attach synchronizer unit of 1st/2nd gear (13).
The marking groove on the collar of the sliding sleeve of the synchronizer unit of 1st/2nd gear (13) must point towards the idler gear of 2nd gear (17). The cams of the synchronizer ring (14) must engage in the cutouts of the synchronizer unit of 1st/2nd gear (13).
D26.50-1238-01
14 Secure synchronizer unit of 1st/2nd gear (13) and idler gear of 2nd gear (17) with assembly clamp (56) and press on as far as the end stop using sleeve.
15 Remove assembly clamp (56).
D26.50-1229-01
16 Install synchronizer ring (12), cone ring (11) and friction ring (10).
The toothing of the synchronizer ring (12) and cams of the cone ring (11) must point towards the output side. The cams of the friction ring (10) must engage in the cutouts of the synchronizer ring (12).
17 Press on bearing bush of 1st gear (9) as far as the end stop using sleeve and install
needle bearing of 1st gear (8).
18 Slide on idler gear of 1st gear (7) and attach thrust plate (6) with the determined thickness.
The cams of the cone ring on the synchronizer unit of 1st/2nd gear (13) must engage in the cutouts of the idler gear of 1st gear (7).
19 Press on bearing bushing of reverse gear (5) as far as the end stop using drift
(711 589 07 15 00).
20 Install needle bearing of reverse gear (4) and idler gear of reverse gear (3).
The collar of the idler gear of reverse gear (3) must point towards the output side.
21 Install synchronizer ring (2) with toothing towards the idler gear of reverse gear (3).
D26.50-1247-03
D26.50-1239-01
22 Secure synchronizer unit of reverse gear (1) using assembly clamp (55) and press on as far as the end stop using drift (711 589 07 15 00).
The marking groove on the collar of the sliding sleeve of the synchronizer unit of reverse gear (1) must point towards the idler gear of reverse gear. The driver of the synchronizer ring (2) must engage in the cutouts of the synchronizer unit of reverse gear (1).
23 Remove assembly clamp (55).
D26.50-1231-01
24 Remove main shaft from workshop press
25 Attach synchronizer ring (28) with clutch body (29) on drive side to the synchronizer unit of 5th/6th gear (27) and secure to prevent it from falling down.
The drivers of the synchronizer ring (28) must engage in the grooves of the synchronizer unit of 5th/6th gear (27).