Assemble main shaft

AR26.50-D-0420-15R

Assemble main shaft

Transmission

711.680/683 in model 909

Adjustment values for gear set

Number

Designation

Transmission 711.680/683 in model 909

BE26.50-N-1007-01D

Protrusion, feeler gauge for determining the package dimensions

"A"

mm

9,97...10,03

1

Mount synchronizer body (25), bearing sleeve (31), thrust plate (34), bearing sleeve (35) and the synchronizer body (39) onto the  plug gauge (42).

2

Protrusion (A) of  plug gauge (42)  Test .

 If the protrusion (A) does not match the specified value, use a thrust plate (34) of the appropriate material thickness. Thrust plates (34) are available in material thicknesses of 5.70 to 6.15 mm in steps of 0.05 mm.

3

Remove synchronizer body (39), bearing sleeve (35), thrust plate (34), bearing sleeve (31) and the synchronizer body (25) from the  plug gauge (42).

4

Press on spacer ring (19) using workshop press.

5

Install green needle bearing for 2nd gear (20).

6

Fit friction ring (22) and cone ring (23) on 2nd gear idler gear (21).

 The cams of the friction ring (22) must point up (toward the output side). The cams of the cone ring (23) must engage in the notches of the 2nd gear idler gear (21).

7

Mount synchronizer ring (24).

 The teeth on the synchronizer ring (24) must point toward the 2nd gear idler gear (21). The cams on the friction ring (22) must engage in the notches of the synchronizer ring (24).

8

Press on the synchronizer body (25).

 The inscription on the synchronizer body (25) must point up (toward the output side). The cams of the synchronizer ring (24) must engage in the notches of the synchronizer body (25).

9

Press on 2nd gear idler gear (21) together with synchronizer body (25) using  sleeve.

 When pressing on, squeeze together the synchronizer body (25) and the 2nd gear idler gear (21) so that the cams of the synchronizer ring, the cone ring and the friction ring do not slide out of their respective notches.

10

Press on bearing sleeve (31) using  drift.

11

Install green needle bearing for 1st gear (32).

12

Install sliding sleeve (27) and thrust pieces (26).

 The groove (arrow A) of the sliding sleeve (27) must point downwards (towards the drive side). Push on the sliding sleeve (27) so that the balls of the thrust pieces (26) then engage in the center groove of the sliding sleeve teeth (arrow B).

13

Mount synchronizer ring (28).

 The synchronizer ring teeth (28) must point up (toward the output side). The cams of the synchronizer ring (28) must engage in the notches of the synchronizer body (25).

14

Attach cone ring (30) and friction ring (29).

 The cams of the cone ring (29) must point up (to the output side). The cams on the friction ring (30) must engage in the notches of the synchronizer ring (28).

15

Install 1st gear wheel (33).

 The cams of the cone ring (29) must engage in the notches of the 1st gear idler gear (33).

16

Fit thrust plate (34) of the determined material thickness and press on bearing sleeve (35) using  drift.

17

Install needle bearing for reverse gear (36) and idler gear for reverse gear (37).

18

Install synchronizer ring (38).

 The teeth of the synchronizer ring (38) must point down (toward the drive side).

19

Press on synchronizer body (39) using  drift.

20

Install sliding sleeve (41) and thrust pieces (40).

 The groove (arrow C) of the sliding sleeve (41) must point downwards (towards the drive side). Push on the sliding sleeve (41) so that the balls of the thrust pieces (40) then engage in the center groove of the sliding sleeve teeth (arrow B).

21

Install roller bearing intermediate plate (17) and outer bearing race (16).

 Clip intermediate plate roller bearing (17) together. The shoulder on the outer bearing race (16) must point down (toward the output side).

22

Install needle bearing for 3rd gear (15).

23

Mount clutch body (13) onto idler gear for 3rd gear (14).

 The shoulder on the 3rd gear idler gear (14) must point up (toward the drive side). The teeth on the clutch body (13) must point downwards (toward output side).

24

Mount friction ring (12) and cone ring (11).

 The cams of the friction ring (12) must point up (toward the drive side). The cams of the cone ring (11) must engage in the notches of the clutch body (13).

25

Mount synchronizer ring (10).

 The cams on the friction ring (12) must engage in the notches of the synchronizer ring (10).

26

Mount synchronizer body (9).

 The labeling on the synchronizer body (9) must point up (toward the drive side). The cams of the synchronizer ring (10) must engage in the notches of the synchronizer body (9).

27

Press on synchronizer body (9) along with idler gear for 3rd gear (14) using  drift.

 When pressing on, squeeze together the synchronizer body (9) and the 3rd gear idler gear (14) so that the cams of the synchronizer ring, the cone ring and the friction ring do not slide out of their respective notches.

28

Insert blocking pieces (6) in the sliding sleeve (5).

 The convex sides of the blocking pieces (6) must rest against the sliding sleeve (5).

29

Install sliding sleeve (5) and thrust pieces (8).

 The groove (arrow E) of the sliding sleeve (5) must point upwards (towards the drive side). Push on the sliding sleeve (5) so that the balls in the thrust pieces (8) then engage in the center grooves of the sliding sleeve teeth (arrow F).

30

Install new retaining ring (7) using  pliers.

 The chamfer on the retaining ring (7) points towards the synchronizer body (9) of the idler gear for 3rd gear (14).

31

Install synchronizer ring (4).

 The cams on the synchronizer ring (4) must engage in the notches of the synchronizer body (9) of the idler gear for 3rd gear (14).

32

Attach cone ring (3) and friction ring (2).

 The cams (a) of the cone ring (3) must point up (toward the drive side). The cams on the friction ring (2) must engage in the notches of the synchronizer ring (4).

33

Install clutch body (1).

 The teeth on the clutch body (1) must point down (towards the output side). The cams of the cone ring (3) must engage in the notches of the clutch body (1).