AR26.50-D-4775-03A Assemble Countershaft
AR26.50-D-4775-03A Assemble Countershaft
- TRANSMISSION 716.622 in MODEL 170.44
716 589 02 33 00
Sleeve
168 589 00 14 00
Sleeve
With the exception of the gearwheels for the 1st gear and reverse gear, the gearwheels fitted in diesel vehicles are different to those in gasoline vehicles.
In order to distinguish between the gearwheels, the gearwheels for diesel vehicles (with the exception of the gearwheels for the 1st gear and reverse gear) have a groove (arrow) in the teeth.
1 Clamp the countershaft in a vise with jaw protectors.
Clamp the countershaft in the vise with the input end facing upwards.
2 Fit 4th gear needle roller bearing (22).
3 Fit 4th gear idler gear (21).
The straight teeth must point upwards.
Risk of confusion!
The clutch bodies (6, 20) for the 3rd and 4th gear differ in the direction of the tooth tips (arrows):
^ 4th gear clutch body (20):
The long side of the point is to the left.
^ 3rd gear clutch body (6):
The long side of the point is to the right.
4 Install 4th gear clutch body (20).
The outer teeth must point downwards (towards the output end).
5 Install the friction ring (19).
The lobe must point up (toward input end).
6 Install synchronizer cone ring (18).
The lobes must engage in the cutouts (arrow) in the clutch body.
7 Install synchronizer ring (17).
The teeth must point downwards (towards the output end).
The lobes in the friction ring (19) must engage in the recesses in the synchronizer ring (17)
Only when required (new synchronizer assembly is supplied as a single unit):
8 Assemble new synchronizer assembly:
8.1 Lubricate with grease and install 3 blocking pieces (10) in the slider sleeve (11).
The grooves in the blocking piece must face inwards.
8.2 Slide sliding sleeve (11) onto 3rd/4th gear synchronizer body (16).
Slide on the sliding sleeve (11) such that the balls (15) will subsequently mesh in the center groove of the sliding sleeve teeth (arrow).
8.3 Insert wide sliders (14), compression springs (13) and balls (15) into 3rd/4th gear synchronizer body (16).
The sliders (14) for the individual synchronizer bodies have different widths:
1st/2nd gear synchronizer body: wide sliders (15 mm)
3rd/4th gear synchronizer body: wide sliders (15 mm)
5th/6th gear synchronizer body: narrow sliders (9 mm)
Reverse gear synchronizer body: narrow sliders (9 mm)
9 Position new 3rd/4th gear synchronizer unit (30) and press on using sleeve.
The orientation groove on the sliding sleeve must face upwards.
The 3 long lobes (arrow) of the synchronizer ring must engage in the recesses of the synchronizer body.
When pressing on the new synchronizer body, swarf may be produced and this must be removed:
Use compressed air to blow off the countershaft.
10 Determine thickness of the circlip (12):
Insert test circlip (thickness: 1.5 mm) using pliers and press downwards all the way (towards output end).
Use feeler gauge to measure gap between test circlip and top edge of groove in countershaft.
Calculate thickness of circlip (= (measured value + 1.5 mm (test ring)).
Remove test circlip using pliers.
11 Use pliers to insert a new circlip (12) with determined thickness (steps of 0.05 mm).
Pay attention to correct seating of circlip (12).
12 Install synchronizer ring (9).
The teeth must point upwards (towards the input end). The 3 long lobes in the synchronizer ring (9) must engage with the recesses in the synchronizer body.
13 Install synchronizer cone ring (8).
The lobe must point up (toward input end).
14 Install the friction ring (7).
The lobes must engage in the cutouts in the synchronizer ring.
15 Install clutch body (6).
The lobes in the synchronizer ring must engage in the cutouts in the clutch body (6).
16 Fit 3rd gear needle roller bearing (5).
17 Fit 3rd gear idler gear (4).
The straight teeth must point downwards (towards the output end).
18 Heat 6th gear fixed gear (3) to approx. 120° C and press on with sleeve.
The collar must point upwards (towards the input end). While pressing on, hold the 3rd gear idler gear in place to prevent the 3rd gear clutch body from jumping out of the lobes of the synchronizer ring.
19 Heat constant-mesh gear (2) to approx. 120° C and press on with sleeve.
The collar must point downwards (towards the output end).
20 Install new circlip (1).
21 Release the countershaft from vise.