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Section 7

TRANSMISSION

7-47

Section 7
7-47

TRANSMISSION - DISMANTLING

1.

Remove filter cartridge

2.

Disconnect and remove clutch feed pipes. Later


machines have hoses instead of pipes which
should be marked for position before removal.

3.

Remove dipstick / filler tube and gasket A.

4.

Remove pump suction pipe, gasket B and O


ring C.

5.

Unscrew mounting bolts and lift off control valve


taking care not to lose detent balls and springs.

6.

Unscrew plugs from both sides of valve and lift


out detent balls and springs.

209

Issue - 1

Section 7

TRANSMISSION

7-48

Section 7
7-48

TRANSMISSION - DISMANTLING (contd)

7.

Remove brake disconnect housing D, release


circlips E and remove spools. Cover F is spring
loaded and care should be taken to release
spring pressure.

8.

9.

Lift off torque converter assembly.

10. Unscrew bolts G and tap off converter housing.

11. To renew bearing, remove small circlip and press


out pump adapter. Release outer snap rings and
push bearing out of housing.

210

Unscrew plug and withdraw 4th speed selector


spool.

12. Unscrew plugs from both sides of valve and lift


out detent balls and springs.

Issue - 1

Section 7

TRANSMISSION

Section 7

7-49

7-49

TRANSMISSION - DISMANTLING (contd)

13. Using a suitable tube, adapters and puller, press


out transmission pump housing. Take care to
position legs of puller on the strongest parts of
the casing. Do Not use jacking holes to withdraw
housing as damage may be caused.

14. Lift out pump and housing assembly from casing.

15. Unscrew bolts H and lift off pump unit from


housing.

16. Remove converter relief valve ball and spring J


and bearing shim K.

17. Release circlip L and tap converter shaft down


to clear bearings and drive gear.

18. Withdraw outer bearing from housing.

211

Issue - 1

Section 7

TRANSMISSION

7-50

Section 7
7-50

TRANSMISSION - DISMANTLING (contd)

19. Remove drive gear.

20. Withdrae inner bearing.

21. Lift out converter drive shaft

22. Release bearing circlip, remove bolts and


separate pump components.

23. Make flanges of clutch shafts to ensure


replacement in correct radial position and
location. Remvoe shaft bolts and position two
bolts in jacking holes provided.

24. Tighten : jacking bolts and lift out clutch shafts.


Note : Clutch shafts are fitted with different size
restrictors and must therefore always be
replaced in their original positions.

212

Issue - 1

Section 7

TRANSMISSION

7-51

Section 7
7-51

TRANSMISSION - DISMANTLING (contd)

25. Withdraw froward/1st and reverse /2nd clutch


assemblies through pump housing aperture.

26. Release idler gear circlip.

27. Remove idler gear spindle.

28. Collect idler gear and components from within


casing.

29. Lift out 3rd/4th clutch assembly through pump


housing aperture.

30. Remove plug and prise out converter relief valve


cartridge. Remove circlip to separate
components.

213

Issue - 1

Section 7

TRANSMISSION

7-52

Section 7
7-52

TRANSMISSION - DISMANTLING (contd)

31. Remvoe both output flanges by prising off


tabwashers and usscrewing bolts.

32. Use a puller to withdraw flanges from output


shaft.

33. Prise out oil seals.

34. Release circlip and remove shim.

35. Tap output shaft and bearing upwards through


gear and collect spacer.

36. Remove two sealing covers by tapping inwards


on one side.

214

Issue - 1

Section 7

TRANSMISSION

7-53

Section 7
7-53

TRANSMISSION - DISMANTLING (contd)

37. Unscrew two baffle plate retaining bolts and


remove top baffle.

38. Remove output gear and lower baffle through


pump housing aperture.

TYPICAL CLUTCH - DISMANTLING

39. Release snap ring and withdraw backing plate


and clutch plates.

40. Compress piston return spring and release


circlip.

41. Remove circlip, spring and spring cups.

42. Remove piston, Dismantle remaining clutches


in a similar manner.

215

Issue - 1

Section 7

TRANSMISSION

Section 7

7-54

7-54

TYPICAL CLUTCH - ASSEMBLY

1.

Fit new piston seals with sealing edge towards


pressure side of piston. Coat seals with grease
and push piston into carrier.

2.

Assemble piston return spring, cups and circlip.

3.

Compress spring and secure circlip

4.

Measure thickness of one drive plate.

5.

Assemble one driven plate into carrier followed


by the drive plate priviously meaured.

6.

Positionthrust plate M onto carrier. Fit thrust


washer N into spur gear using grease to retain
it in position. Place spur gear carrier with splines
resting on top of drive plate. i.e. Splines not
engaged.

216

Issue - 1

Section 7

TRANSMISSION

7-55

Section 7
7-55

TYPICAL CLUTCH - ASSEMBLY (contd)

7.

Position assembly onto straight-edge or surface


plate. Measure depth from face of spur gear to
straight-edge and add thickness of drive plate
(operation 4). Repeat measurement with splines
of spur gear engaged in drive plate. First
measurment must be greater than full
engagement of splines and drive plate.

9.

Measure end float of backing plate which should


be 2.0 2.7mm (0.08 0.10 in). Drive plates are
available in varying thickness to correct in a
similar manner.

8.

Remove spur gear and fit alternate driven plates


and drive plates. Fit backing plate and secure
with snap ring.

Note : Before installing ball bearing into 1st speed


spur gear, coat outside diameter with JCB High
Strength Retainer.

217

Issue - 1

Section 7

TRANSMISSION

7-56

Section 7
7-56

TRANSMISSION - ASSEMBLY
(See page 1/1-3 for torque settings)

1.

When fitting a new output shaft roller bearing


head up inner track to approximately 150oC (see
stage 2) and press onto gear hub, shoulder
towards gear.

2.

Direct heating should not be used on inner track.


Heat a round bar and place inside inner track
as shown.

3.

Fit circlip into bearing bore and fit outer race


and rollers. Use petroleum jelly to hold rollers in
position.

4.

Place output gear together with lower baffle in


position through pump housing aperture and
locate onto bearing taking care not to dislodge
rollers.

5.

Slide output shaft, with spacer but without front


bearing, into position within the output gear and
push fully home.

6.

Measure distance between end face of shaft


kand shoulder of bearing land.
e.g. 78.30 mm

218

Issue - 1

TRANSMISSION

Section 7

Section 7

7-57

7-57

TRANSMISSION - ASSEMBLY (contd)

7.

Measure distance between end face of shaft and


bearing inner circlip. e.g. 78.90mm.
Example :

8.

If the end paly is incorrect, a shim X should be


fitted under the outer race of the roller bearing.

9.

Cross section of output shaft assembly showing


shim X in position

Dimension 6 = 79.30 mm
Dimension 7 = 78.90 mm
Dimension

0.40 mm

The roller bearing must have an end play of 0.30


to 0.50 mm. In the example above the end play
is correct; proceed to stage 11.

10. Replace output gear and lower baffle taking care


not to dislodge rollers.

219

11. Fit top baffle and secure with bolts.

Issue - 1

Section 7

TRANSMISSION

7-58

Section 7
7-58

TRANSMISSION - ASSEMBLY (contd)

12. Coat outside diameter of new sealing covers with


JCB Multi-Gasket and tap into position.

13. Position output shaft and bearing through spacer


and output gear and tap down until bearing seats
firmly onto circlip.

14. Select shim to eliminate end float when circlip is


fitted. Fit shim and circlip.

15. Coat outside diameter of new oil seal with JCB


Mulit-Gasket and install to 22mm (0.86 in) below
end face of shaft. Repeat procedure for other
seal.

16. Grease lips of seal and fit output flange. After


tightening blots coat contact face of lockplate
with JCB Mulit-Gasket and tap into position.
Repeat for outer output flange.

17. Assemble converter relief valve and tap into


position at bottom of bore. Fit plug.

220

Issue - 1

Section 7

TRANSMISSION

7-59

Section 7
7-59

TRANSMISSION - ASSEMBLY (contd)

18. Lay 3rd/4th clutch thrust plate and thrust washer


into casing, checking location of ears. Grease
lightly to retain in position.

19. Enter 3rd/4th clutch pack into casing and position


carefully over thrust washer.

20. Lay a new gasket noto clutch shaft mounting


face and measure depth to bearing rollers.
Subtract from this the clutch pack end float which
whould be 0.30 0.50mm (0.012 0.019 in).

21. Measure depth from bearing thrust face on fhaft


to face of mounting flange. Subtract this from
dimension calcutated at fig. 20 to establish
thickness of clutch pack shim.

22. Move clutch pack to one side and palce selected


shim P underneath thrust plate. Grease lightly
to hold in position.

23. Reposition clutch pack and use mandrel, tool


no. 992/10300 to align components.

221

Issue - 1

Section 7

TRANSMISSION

7-60

Section 7
7-60

TRANSMISSION - ASSEMBLY (contd)

24. Apply grease to piston ring seals on shaft. Using


a new gasket coated with JCB Multi-Gasket
carefully enter shaft into bore and secure with
bolts.

25. Position idler gear and thrust washers inside


casing and using a new gasket coated with JCB
Multi-Gasket enter spindle into casing. Fit
retaining washer, pin and circlip before finally
tightening bolts and nuts.

26. Assemble forward/1st and reverse/2nd clutch


packs into casing by repeating operations 18 to
23. Install reverse/2nd clutch first and displace
radially until forward/1st clutch is installed.

27. Grease piston ring seals on shafts and fit using


new gaskets coated with JCB Multi-Gasket.
Tighten securing bolts.
Note : Ensure that shafts are fitted correctly in
their original bores.

28. Assemble oil pump components, fit shaft and


secure with circlip.

29. Grease piston ring on converter drive shaft and


push shaft fully down into pump housing.

222

Issue - 1

Section 7

TRANSMISSION

7-61

Section 7
7-61

TRANSMISSION - ASSEMBLY (contd)

30. Tap inner bearing fully into its bore.

31. Slide gear into position then tap converter drive


shaft upwards to engage splines.

32. Tap outer bearing into position and secure with


circlip L.

33. Laya new gasket onto pump flange and measure


from bearing outer race to gasket. Ensure
bearing outer race is pushed fully down.

34. Measure depthof counterbore in pump body and


subtract from bearing outer race dimension (fig.
33)

35. Subtract bearing end float 0.30 to 0.50 mm


(0.012 to 0.019 in) from final dimension (fig.
34) to establish thickness of shim K. position
shim over bearing and assemble relief ball and
spring J.

223

Issue - 1

Section 7

TRANSMISSION

7-62

Section 7
7-62

TRANSMISSION - ASSEMBLY (contd)

36. Assemble pump to housing and tighten bolts H.

37. Apply JCB Multi-Gasket to pressure ports of


pump housing and casing as shown.

38. Using a new flange gasket coated with MultiGasket carefully tap pump housing into casing
whilst checking that drive gear teeth mesh with
clutch spur gears.

39. Coat outside diameter of new oil seal Q with JCB


Multi-Gasket and tap down flush with housing.
Smear lips of seal with grease.

40. Fit converter housing and secure with bolts G.

41. Assemble loader pump drive bearing into flange


whilst holding snap rings open. Fit drive hub
through bearing and secure with small circlip.

224

Issue - 1

Section 7

TRANSMISSION

7-63

Section 7
7-63

TRANSMISSION - ASSEMBLY (contd)

42. Fit loader pump drive to casing using a new


gasket coated with JCB Multi-Gasket.

43. Carefully lower torque converter into position


whilst turning it to engage splines.

44. Assemble 4th speed selector spool and refit plug


using a new sealing washer.

45. Assemble main valve block ensuring that spool


seals are fitted with lips facing inward.

46. Apply grease to detent balls and spring to hold


them in position. Secure with plugs.

47. Place sandwich plate in position with a new


gasket each side then position check valve balls
and spring as shown.

225

Issue - 1

Section 7

TRANSMISSION

7-64

Section 7
7-64

TRANSMISSION - ASSEMBLY (contd)

48. Lower valve block into position taking care not


to disturb the ball and springs. Tighten securing
bolts in a diagonal sequence to 25 Nm
(18.4 lbf ft).

49. Apply JCB Multi-Gasket to a new gasket B and,


using a new O ring C, fit pump suction pipe.

50. Coat new gasket A with JCB Multi-Gasket and


fit dipstick/filler tube.

51. Fit clutch feed pipes using new sealing washers.


Later machines are fitted with hoses instead of
pipes.

52. Smear seal of new filter cartridge with oil and


screw into position.

226

Issue - 1

TRANSMISSION

Section 7
7-65

Section 7
7-65

1. ELECTRO - HYDRAULIC
GEARSHIFT SYSTEM
See also Illustrated Table Page 13 and 15
Control valve assembly with 2-stage control pressure
valve, 4 magnets and breather valve.
(AI-Gearshift housing) AI = Aluminium
1

1.1 Disassembly
Remove delivery line (1st speed to the 2-stage valve).

Loosen socket head screws and remove control valve


assembly.
Remove gasket and intermediate plate.
Remove delivery lines, loosen socket head screws
and separate channel plate from gear case.
Note: Pay attention to the released balls and springs!
Use two adjusting screws!
(S) Adjusting screws (M 8)

5870 204 011

Remove delivery line.

227

Issue - 1

Section 7

TRANSMISSION

7-66

Section 7
7-66

Relax spring clip and remove cover.

Pull off cable shoes and remove cable harness.


Loosen socket head screws and remvoe solenoid
valves.

Remove components, see Figure 1

Loosen socket head screws and fix gearshift housing


provisionally, using Special Tool (S).
Now, loosen the remaining socket head scews and
separate the gearshift housing (is spring-loaded).
from the valve body by loosening the nuts (S) evently.
(S) Adjusting scerws (M 5)

5870 204 036

228

Issue - 1

Section 7

TRANSMISSION

7-67

Section 7
7-67

Dismantle pressure control valve.

Remove components.

10

Remove stop plate (Arrows) and detent blocks (2 x).

11

229

Issue - 1

TRANSMISSION

Section 7
7-68

Section 7
7-68

1.2 Reassembly
Note : Inspect all componenst for damage and renew
if necessay.
check free travel of the moving parts in the housing
prior to the installation.
Spools can be exchanged individually !
Lubricate components prior to the reassembly ! in
the following Reassembly Instructions, empirical
values are indicated for several shims ! If deviations
are encountered during the final test bench run,
correct by means of corresponding shims!
Close the bores by means of ball (8pieces, 4, 5
mim).

12

Introduce detent blocks (1 and 2) in the bores and


fix them by means of the stop plates (3 and 4).
Install detent block (5).
Note : The illustration on the left shows theinstallation
position of the components.

13

Install components.
1 = Spool
2 = Spring

(Total length 86,00mm)


(Lo = 53,40mm)

Note :
Lo = Length of the unloaded spring !

14

230

Issue - 1

TRANSMISSION

Section 7
7-69

Section 7
7-69

Reset valve :
Install components.
1 = Spool
2 = Washer (s)
3 = Spring
4 = Spring

(empirical value = 5,20mm)


(Lo = 58,00mm)
(Lo = 65,40mm)

15
Pressure control valve :
Install components :
1 = Spool
2 = Spring
3 = Spring
4 = Spool

(Lo = 132,40mm)
(Lo = 76,70mm)

16
Control pressure valve :
Install components :
1 = Spring
2 = Spring
3 = Washer (s)
4 = Washer (s)
5 = Spool
6 = Sleeve

(Lo = 132,40mm)
(Lo = 76,70mm)

17
Pre-assemble 2-stage pressure control valve with
breather valve (Figure 18-20) :
Install orifice (D = 0,70mm).
Note : Wet threads of orifice with Loctite (Type No.
270)!

18

231

Issue - 1

Section 7

TRANSMISSION

Section 7

7-70

7-70

Install components :

2
3

1 = Intermediate plate
2 = Valve
3 = Compression spring
(Lo = 29,90 mm)
4 = Straight pin
(4 h 8 x 25 mm)
5 = Cylinder
6 = Spool
7 = Spring
(Lo = 70,90 mm)
8 = Washer(s)
(Empirical value s = 3,00 mm)
9 = Screw plug
(install new O-Ring)

4
5
6
7
8
9
19

Note : Insert compression spring (3) and valve (2) in


the bore, preload and fix by means of straight pin
(4)!
5 mm).
Close bore (Arrow) by means of ball (

20

Install components and fix by means of socket head


screws and !I~t ~a_shers (Figure 21 and 22) :
1 = Gasket
2 = Block assembly
3 = Ring
4 = Spool
5 = Gasket 6 = Cover
7 = O-Ring
8 = Screw plug

4 3
8

Note : Pay attention to the different thickness of the


rings (3) !

7 6

1
21

Empirical value s = 6,00 mm!


Torque limit (M 5/8.8)
(S) Adjusting screws (M 5)

5, 5 Nm
5870 204 036

22

232

Issue - 1

Section 7

TRANSMISSION

Section 7

7-71

7-71

Install components :
1 = Spring
2 = Spool
3 = Spring
4 = Spool
5 = Spool
6 = Spring
7 = Retaining plate
8 = Socket head screw
9 = Spring
10 = Spool

(Lo = 53,40 mm)


(Lo = 53,40 mm)
(Reducing valve)
(Lo = 37,10 mm)

(Lo = 53,40 mm)

1
2

6
4

7
8

10

23

Note : Pay attention to the installation position of the


components, see Figure 23!
Torque limit (M 5/8.8)

5,5 Nm

Insert solenoid valves and fix them by means of


retaining plate and socket head screws.
Torque limit ( M 5/8.8)

3,5 Nm

Note: Pay attention. to the radial installation position


of the sole:noid valves, see Figure 26 !

24

Install cable harness.


Note : Install new gasket 1
Pay attention to the position of the projection, see
Arrow !

25

233

Issue - 1

Section 7

TRANSMISSION

Section 7

7-72

7-72

Connect solenoid valves according to the Figure on


the left.

26
Install new O-Ring (164,2 x 6,7 mm) see Arrow and
fix cover by means of spring clip.

27
Install delivery line, control pressure sensor
(accord!ng to the design) and screw plug.
2
Note : Install new seal rings and O-Rings !

1 = Delivery .line
2 = Control pressure sensor, resp. screw plug
Torque limit (M 12 x 1,5)

40 Nm

28

1.3 Pre-Assemble channel plate :


Install orifice for the backfeed D = 1,00 mm (Arrow
1), set screw M 5 x 6 mm (Arrow 2) and secure by
caulking

29

234

Issue - 1

Section 7

TRANSMISSION

7-73

Section 7
7-73

Install connecting socket (3 x) and screw plug (Arrow).


Note : Use the O-Rings!
The occupation of the connecting sockets may be
different according to the design!

30
Insert the two check valves (composed of balls and
springs) with grease in the countersinking of the
chaooel plate (see Arrows).

31

1.4 Attach channel plate and gearshift system :


Install components.
Install housing gasket, intermediate plate and 2nd
gasket.
(S) Adjusting screws (M 8)

5870 204 011

32

Assemble AI=Channel plate and fasten it by means


of socket head screws.
Torque limit (M 8/8.8 DIN 912)
Torque limit (M 8/8.8 DIN 6912)
(Flat head)

23 Nm
16 Nm

Item 1 = Socket head screws 3 pieces M 8 x 30


(DIN 6912)
Remaining socket head screws 9 pieces M8 x 40
(DIN 6912)

235

33

Issue - 1

Section 7

TRANSMISSION

7-74

Section 7
7-74

Assemble 1 st gasket.
Note : Pay attention to the different gaskets. see
Figure 34 (Arrow) and Figure 35 !

34
Assemble intermediate plate (Arrow) and 2nd gasket.

35

Place control valve assembly against shoulder and


fasten it by means of socket head screws.
Note : Use flat washers !
Pay attention to the location of the different socket
head head screws (lengths)!
Torque limit

20 Nm

36

Install delivery lines according to Figure 37 and 38.


See also Draft, Page 17.
Note : Use new O-Rings !

37

236

Issue - 1

Section 7

TRANSMISSION

7-75

Section 7
7-75

Install connecting line KV to K1, see Arrow !

38

237

Issue - 1

TRANSMISSION

Section 7
7-79

Section 7
7-79

2. GEAR BOX
2.1 Disassembly
2.1.1 Converter - Drive:
Illustration on the right shows the Version with sheetmetal converter (gearshift system already removed).
Remove suction and filler pipe (Arrows). Remove
adapter, resp. filter
(S)
(S)
(S)
(S)

Assembly car
Clamping bracket
Clamping bracket
Lifting device

5870 350 000


5870 350_014
5870 350 036
5870 350 041

40

Tilt housing 90.


Remove orifice.
Note : Screws are covered with Loctite!

41

Remove the converter.

42

2.1.2 Converter charge and control pressure


pump :
Loosen screwed connection and remove engine
compartment.

43

241

Issue - 1

TRANSMISSION

Section 7

Section 7

7-80

7-80

Loosen hex. head screws on the bearing cap. Tap


bearing cap loose and separate it from the oil supply
flange.

44

Fasten back-off device by means of hex. head screws


on the oil supply flange.
Pull converter charge and control pressure pump
(compl.) out of the housing bore.
(S) Back-off device

5870 000 062

45

Loosen hex. head screws and separate pump from


oil supply flange.
Note : Pay attention to the released converter relief
valve (ball and spring)!

46

Remove rectangular ring (1) and circlip (2).

2
47

242

Issue - 1

Section 7

TRANSMISSION

7-81

Section 7
7-81

Press shaft in direction of the Arrow out of the pump


casing.

48
Loosen hex. head screws, remove pump cover and
remove gear set.
Note : If traces of wear are encountered in the pump
casing as well as in the pump cover, resp. if the
admitted end play would be > 0,05 mm (Figure 50),
the complete pump must be renewed !
Now, complete the pump again.
(S) Depth gauge

5870 200 072


49

50

Remove converter relief valve (ball and spring) and


squeeze out circlip.

51

243

Issue - 1

Section 7

TRANSMISSION

7-82

Section 7
7-82

Press drive shaft in direction of the Arrow until the


spur gear gets free.

52
Pry roller bearing out of the bore. remove released
spur gear.
(S) Adjusting spanner

5870 400 001

53

Remove drive shaft in direction of the Arrow.

54

Pull roller bearing out of the bore.


(S) Internal puller
(S) Back-up tool

5870 300 005


5870 300 003

55

244

Issue - 1

Section 7

TRANSMISSION

7-83

Section 7
7-83

2.1.3 Converter control valve and power take off:


Remove screw plug and temperature adapter
(Arrow)

56
Squeeze out circlip and take out Converter control
valve.

57
Tilt gear case 180.
Loosen hex. head screws, rasp. hex. nuts. Lift power
take-off out of the case.

58

Squeeze out circlips, at the same time tap the


complete driving pin loose (direction of Arrow) and
drive it out.

59

245

Issue - 1

Section 7

TRANSMISSION

7-84

Section 7
7-84

2.1.4 Remove the multi-disk clutches KV/K1 KR/


K2, layshaft and K3/K4 :
Loosen hex. nuts, resp. screws of both axles (KV/ K1
and KR/K2) and remove connections, see Arrow.
Now, pull the two axles out of the clutches, resp. the
gear case,-using special device.
(S) Puller device

5870 000 069

60

Remove the two clutches.


Note : Pay attention to the released washers and
bearing rollers !
(S) Lifting device

5870 281 035

61

The Illustration on the left shows the clutch KR/K2

62

246

Issue - 1

Section 7

TRANSMISSION

7-85

Section 7
7-85

Layshaft with reverse gear :


Remove hex. head screws from reverse gear, remove
washer.
Note : Screw is secured with Loctite !

63
Loosen screws of the Layshaft and remove it
downwards.
Take off spur gear upwards.
If necessary, remove angle ring.
Note : Pay attention to the released bearing rollers.

64

Remove clutch K3/K4 (Figure 60 and 61) accordingly.


The Illustration on the right shows the removed multidisk clutch K3/K4.

65

247

Issue - 1

Section 7

TRANSMISSION

7-86

Section 7
7-86

2.1.5 Multi-disk clutches:


Remove spur gear and take out the released
components.

67
Squeeze out snap ring.

68

Remove plate stack.


On the opposite side, disassemble clutch KV
accordingly.

69
Preload compression spring.
Remove circlip and components.
(S) Assembly jig

5870 345 028

70

248

Issue - 1

Section 7

TRANSMISSION

7-87

Section 7
7-87

Remove piston by means of clampi~ pliers.


Note : A slight rotation would help to remove the
piston !

71
If necessary, remove the needle bearing from the
piston carrier.
Note : Carry out the disassembly of clutch KV, KR/
K2 and K3/K4 accordingly.

72

249

Issue - 1

TRANSMISSION

Section 7
7-89

Section 7
7-89

Rotate gear case 180.


Remove lock plate and loosen screws.

82

Pull off output flange.


(S) Two-leg puller

5870 970 006

83

Tap loose output shaft and drive it out of the gear


case.

84

Take second half of the baffle plate and spur gear


out of the case.

85

251

Issue - 1

TRANSMISSION

Section 7
7-90

Section 7
7-90

Remove shaft seal and circlip.


Drive roller bearing out of the case.

86

Loosen hex. head screws in the housing inside and


press the~two anchor pins out of the gear case, using
pry bars.
Note : Hex. head screws are installed with Loctite!
(S) Puller device
(S) Pry bar

5870 000 066


5870 345 036

87

252

Issue - 1

Section 7

TRANSMISSION

Section 7

7-91

7-91

2.2 Reassembly
2.2.1 Gear case :
Install studs according to the Illustration on the right.
Torque limit (M 8/8.8)

9 Nm

Note : Use Loctite Type - No. 270 !


Tilt gear case 180o.
95

Fasten baffle plate for breather in the area of the oil


filter, resp. adapter by means of hex. head screws
(see Arrow).
Note : Secure hex. head screws with Loctite TypeNo. 270 !
Torque limit (M 8/8.8).

23 Nm

96
Install screw plug with seal ring (see Arrows).

97

2.2.2 Parking brake :


2
Insert a-Ring (3) s = 25,3 x 2,4 in the anchor pin .
(1) and install it in the housing bore.

Start pin from the inside along with shim (4)


s = 6mm, flat washer and hex. head screw, cover it
with Loctite Type - No. 270 and fasten.
Torque limit

49 Nm

Grease 2nd a-Ring (3) and insert it in the anchor pin


groove (2) and with assembled brake cam into the
housing bore (see also Draft. Page 34).

253

98

Issue - 1

Section 7

TRANSMISSION

7-93

Section 7
7-93

Introduce oil baffle plate (4) through the large housing


bore and lay it upon the roller bearing (3) see Draft.
Note : Pay attention to the location of the oil baffle
plate !

100

Insert spur gear with replaced bearing inner race


(5) (see Arrow) through the housing bore in the
already installed bearing outer race (3).

101

Squeeze circlip (6) into the lower groove of the


housing.

102

Mount heated speedometer drive worm (7), resp.


spacing tube (according to the Version) upon the drive
shaft.

103

255

Issue - 1