Disassemble Transmission and Transfer Gear
Illustration shows the transmission in installed position.
Make identification and remove the oil lines.
Mark housing, cover and downshift inhibitor.
Loosen and remove allen head screws.
NOTE: Allen head screws are secured with Loctite.
Install two adjusting screws (guide bolts).
Tap loose and remove the downshift inhibitor valve from bearing cover.
(S) adjusting screws
Squeeze out snap ring and remove the shaft seal.
Illustration shows the components of the downshift inhibitor valve.
Loosen locknut and remove both oil supply pistons.
Remove valve (centrifugal governor).
Pull off valve body from shaft.
Squeeze out circlip (snap ring) and remove it together with spacing washers.
Remove O-rings.
Loosen the allen head screws.
NOTE: Allen head screws are secured with Loctite.
Install two adjusting screws (guide bolts).
Back off clutch housing assembly and remove it.
(S) adjusting screws
Separate complete bearing cage from clutch housing.
(S) pry bars
(S) magnetic blocks
Remove the snap ring and pull off the inner plate carrier.
Separate shaft from the complete bearing cage.
Unhook rectangular rings (set of 3) and remove them.
If required, pull off bearing inner race.
(S) two-leg bearing puller
Clutch B
Squeeze out circlip.
Lift out transmission clutch pack assembly.
NOTE: The larger clutch pack is for second (fast) speed, and the smaller clutch pack is for first (slow) speed.
Preload compression spring by means of the special tools.
Squeeze out circlip, remove plate and cup spring.
(S) assembly jig
(S) centering disc
Press piston out of the clutch bell housing, using compressed air at the drilled passage.
Squeeze out circlip.
Pull off clutch bell housing.
Pay attention to the released washer and annular seal ring.
Squeeze out circlip.
Drive spur gear assembly out of the bearing cage with a soft hammer.
Remove the snap ring and remove shaft seal.
Remove the snap ring from the spur gear.
Lift out shaft seal and remove both roller bearings.
Unhook rectangular ring and remove it.
Squeeze out the snap ring and remove spacing washers.
Pull off ball bearing with a bearing puller.
Remove remaining spacing washer and snap ring.
(S) two-leg bearing puller
Clutch A
Squeeze out circlip.
Take out the clutch pack, (discs and plates).
NOTE: The larger clutch pack is for second (fast) speed, and the smaller clutch pack is for first (slow) speed.
Preload compression spring by means of special device and squeeze out circlip.
Remove spring guide and compression spring.
(S) assembly jig
Squeeze out circlip.
Pull off clutch bell housing from drive shaft.
(S) adjusting spanner.
Remove sealing disc.
Press piston out of the clutch bell housing, using compressed air.
Loosen allen head screws.
Carefully drive the complete drive shaft out of the clutch housing with a soft punch.
Remove the rotor.
Pay attention to the released drive pin.
Remove O-ring and both rectangular rings.
Pull needle bearing out of the drive shaft.
(S) internal puller
(S) support
(S) magnetic block
Squeeze out the snap ring.
Remove shaft seal (is damaged at removal).
Remove the second snap ring and remove the pump cover.
Squeeze out both circlips.
Pull off ball bearing from drive shaft.
(S) two-leg puller
Loosen hex head screws from the transfer gear housing.
NOTE: Screws are secured with Loctite.
Install two adjusting screws (guide bolts) and tap loose and remove bearing cover from the housing.
(S) adjusting screws
Squeeze out the snap ring, remove spacing washers and drive out roller bearing starting from the rear.
Loosen hex head screws.
NOTE: Screws are installed with Loctite.
Install two adjusting screws (guide bolts).
Tap loose and remove cover.
(S) adjusting screws
Remove O-ring and lift out shaft seal.
Unlock hex nut.
Remove hex nut and lock plate.
(S) fixture
Pull spur gear out of the transfer gear housing.
Mark oil baffle plate with housing.
Loosen hex head screws and remove oil baffle plate.
NOTE: Pay attention to released spacing sleeves (set of 3).
Mark transfer gear case with axle housing, see arrows.
Loosen allen head screws.
Install two adjusting screws (guide bolts) and separate transfer gear case from axle housing.
(S) adjusting screws
Drive out bearing pin with a soft punch and remove released idler gear as well as thrust washers from the housing.
Remove both roller bearings and washer out of the idler gear.
Assemble Transmission and Transfer Gear
Install first roller bearing into idler gear, replace thrust washer and install second roller bearing.
NOTE: Grease the components.
Cover both thrust washers with grease and make them adhere in the housing.
NOTE: Pay attention to the installation position.
Insert O-rings into both grooves of the bearing pin.
Install idler gear and fix it by means of bearing pin.
NOTE: Pay attention to the installation position of the idler gear.
Install two adjusting screws (guide bolts), flat gasket and place the transfer gear housing against the axle, until contact is obtained.
NOTE: Pay attention to the location, see markings made at disassembly.
(S) adjusting screws
Fasten the transfer gear housing by means of allen head screws.
Torque limit (M14/12.9) 190 N·m
Install oil baffle plate.
NOTE: Use spacing sleeves. Pay attention to the markings. Oil baffle plate position is depending upon the installation position of the transmission.
Cover hex head screws threads with Loctite.
Torque limit (M6/8.8) 10 N·m
Guide spur gear over drive shaft splines until contact is obtained.
Install washer and tighten hex nut.
Torque limit 550 N·m
(S) fixture
Bend the lock plate against the shoulder of the nut. Fill the slot with caulk or sealing compound to make it watertight.
(S) driver
(S) handle
Cover O-ring with grease and insert it into the groove, see arrow.
Drive shaft seal against shoulder.
NOTE: Fill shaft seal sealing lip with grease.
(S) driver
(S) centering sleeve
(S) handle
Install two adjusting screws (guide bolts), place cover against housing until contact is obtained and fasten by means of hex head screws.
NOTE: Cover hex head screws threads with Loctite.
Torque limit (M12/8.8) 86 N·m
(S) adjusting screws
Drive roller bearing into connection cover until contact is obtained.
Engage circlip and determine shim thickness (bearing will be adjusted without end play).
Squeeze out circlip.
Insert determined shims and fix them by means of circlip.
Cover both O-rings with grease and insert them into the cover groove.
Install two adjusting screws (guide bolts) and place cover against housing until contact is obtained.
NOTE: Pay attention to the installation position, see markings made at disassembly.
(S) adjusting screws
Fasten cover by means of hex head screws.
NOTE: Cover hex head screw threads with Loctite.
Torque limit (M10/10.9) 69 N·m
Install ball seat valves into the clutch housing.
Arrangement and installation position, see illustration.
Install needle bearing into the drive shaft until contact is obtained.
Cover O-ring with grease and insert it into the groove.
Squeeze both new rectangular rings into the groove and engage them.
Engage lower snap ring.
Heat bearing in hot oil and place it against snap ring until contact is obtained.
Fix ball bearing with upper snap ring.
| NOTICE |
|---|
Heat bearing cones and races in hot oil to a maximum temperature of 135°C (375°F), when necessary for their installation. |
Install drive shaft into pump cover and fix it by means of the snap ring.
Cover shaft seal with sealing compound and drive it firmly against shoulder.
NOTE: Fill sealing lip with grease.
(S) pressing sleeve
Install the snap ring.
Make rotor adhere with grease and fix it against radial displacement by means of adjusting pin.
Grease O-ring and insert it into the groove of the clutch housing.
Put grease on the rectangular rings (this will facilitate the drive shaft assembly), and install complete pump cover into the clutch housing.
Use new sealing rings (Usit-rings) for socket head screws.
Position pump cover uniformly by means of socket head screws, until contact is obtained.
Torque limit (M6/8.8) 10 N·m
Assemble Clutch A:
Grease both O-rings and insert them into the piston.
Install piston into the clutch bell housing.
Install compression spring and place spring guide upon it.
Press spring against piston, using special device and fix it by engaging the snap ring.
(S) assembly jig
Insert the clutch plate pack, starting with two outer plates (10 plates), and then alternating one inner plate (9 plates) as well as one outer plate etc.
Install pressure plate and fix it by means of snap ring.
Check the pressure plate end play, 2.2 + 1.5 mm.
Charge the clutch plate pack with 200 N.
Measure dimension A from plane surface clutch bell hosuing to pressure plate with a depth micrometer.
For Example: 13.80 mm
Press backing plate axially against snap ring.
Determine dimension B from plane surface clutch bell housing to pressure plate.
For Example: 10.80 mm
Example:
If the clearance is tighter than 2.20 mm, use a thinner snap ring (s = 2.00 mm).
Guide pre-assembled clutch A over the drive shaft splines until contact is obtained.
Grease O-ring and insert it into the groove of the sealing washer.
Fix clutch by means of sealing washer and snap ring.
Check performance of clutch A by means of compressed air as shown in the illustration.
Install the shaft seal, with the sealing lip towards the oil channel firmly into the centering washer, until contact is obtained.
(S) driver
(S) handle
Install the snap ring.
Grease O-rings and insert them into the groove.
Drive in dowel, see arrow.
Adjust the ball bearing free of end play.
For this purpose, insert ball bearing, engage circlip and determine shim thickness.
For Example: 1.00 mm
Remove ball bearing again.
Guide circlip and shim, determined under figure 103 (for example, s = 1.00 mm) over the helical gear shaft.
Press ball bearing firmly against shoulder and engage the snap ring.
End play = determine shim thickness.
For Example: 1.50 mm
Squeeze out snap ring, install the shim, determined under figure 105 (for example, s = 1.50 mm) and install the snap ring again.
Install the new rectangular ring and engage it.
Install both roller bearings.
Install the shaft seal firmly against shoulder.
Install the snap ring.
Insert pre-assembled helical gear shaft into centering washer until contact is obtained.
Fix helical gear shaft by means of shim and snap ring.
Assemble Clutch B
Grease O-ring and insert it.
Insert piston with installed O-ring into the clutch bell housing.
Insert cup spring into clutch bell housing and fix it radially by means of centering washer.
Press cup spring against piston, using special device, install locking washer and engage snap ring.
(S) assembly jig
(S) centering disc
Install the clutch plate pack, starting with two outer plates (7 plates), then alternating one inner plate (9 plates) as well as one outer plate.
NOTE: On the piston side, install one thicker outer plate.
Install backing plate and fix plate pack by means of snap ring.
Check the plate end play, 1.3 + 1.5, -0.0 mm.
Go ahead as shown under figure 95 and 96.
If the plate play is tighter than 1.30 mm, use thinner snap ring (s = 1.50 mm).
Install the new rectangular ring and engage it.
Guide pre-assembled clutch B over the splines of the helical gear shaft, until contact is obtained.
Grease O-ring, insert it and install subsequently washer.
Fasten the clutch by means of the snap ring.
Check performance of clutch B by means of compressed air as shown in the illustration.
Insert shaft until contact is obtained.
Align the clutch plate pack of clutch A by means of inner plate carrier.
Replace fitting of hose pipe of clutch A by connection for compressed air hose and fix plate pack by means of compressed air.
Remove inner plate carrier.
| NOTICE |
|---|
Be sure the thread size is the same, so damage will not be caused to the housing. |
(S) compressed air connection
Guide inner plate carrier over shaft splines and fix by means of the snap ring.
Align the clutch plate pack by means of profiled ring and fix with compressed air.
Figure shows profiled ring instead of the clutch bell housing.
(S) profiled sleeve
Insert pre-assembled clutch, centering washer and shaft into the clutch housing, clutch A.
NOTE: Pay attention to the radial location of the oil bores (centering washer/clutch housing) for clutch B.
(S) compressed air connection
Flange facing/clutch housing must be in plane (even) with face/centering washer.
This is to be sure that all plates of both clutches have been received.
Heat bearing inner race in hot oil and install it until contact is obtained.
Install the new three rectangular rings on the end of shaft and engage them.
Install two adjusting screws (guide bolts) and place clutch housing assembly against the transfer gear housing until contact is obtained.
NOTE: Pay attention to the location of the dowel in the centering washer towards the bore in the housing.
(S) adjusting screws
Fasten clutch housing to the transfer gear housing by means of allen head screws.
NOTE: Cover socket head screws threads with Loctite.
Torque limit (M12/10.9) 120 N·m
Assemble washer and engage the snap ring.
Adjust end play 0.00 - 0.20 mm.
For this purpose, determine distance between washer and snap ring and adjust the end play by installation of corresponding shims.
Put grease on both O-rings and install them on the shaft.
Cover corrugated washer with grease and insert it into the shaft bore.
Guide valve body over the drive shaft end until an overlapping of the bores (valve body/shaft) has been obtained.
NOTE: Pay attention to the installation position, big collar of valve body showing towards the transfer gear housing.
In order to secure a perfect alignment of the valve body upon the shaft, it is necessary to install the right oil supply piston first (see illustration).
During this installation, the centrifugal valve bore must be installed upward, as shown in the illustration.
Install the oil supply piston on the left side.
NOTE: Grease O-rings of oil supply pistons slightly.
Torque limit 15 N·m
Fix both oil supply pistons by means of locknut.
Torque limit 28 N·m
Install valve (centrifugal governor) with spring into the bore as shown in the illustration.
Grease O-ring, insert it into the screw plug groove and tighten the screw plug.
Torque limit 46 N·m
Install the shaft seal into the housing of the downshift inhibitor valve until contact is obtained.
(S) driver
Install the snap ring.
Illustration shows arrangement of pistons and valves in the housing of the downshift inhibitor valve.
Install gearshift valve in the housing of the downshift inhibitor valve, according to the illustration.
NOTE: Grease O-ring on the screw plug.
Torque limit 70 N·m
Install the reverse piston with spring into the bore and tighten screw plug.
NOTE: Grease O-ring on the screw plug.
Torque limit 35 N·m
Install ball and detent sleeve into the housing.
Tighten both screw plugs.
NOTE: Grease O-rings on the screw plugs.
Torque limit 35 N·m
Install guide bolts and install the assembled downshift inhibitor valve firmly against shoulder.
NOTE: Pay attention to the location, see markings made at disassembly.
(S) guide bolts
Fasten the valve by means of allen head screws.
NOTE: Cover allen head screws threads with Loctite.
Torque limit (M10/8.8) 49 N·m
Install both oil lines as shown in the illustration.