Adjustment of Clutch Clearance for Single Clutch 25-2.1 Model 404.0 Readjust clutch clearance following each removal and installation of single clutch or clutch slave cylinder. New adjustment or re-adjustment is required at certain intervals as the result of normal wear of chlutch facing. These intervals depend on application of vehicle. The adjustment must be checked at the latest at intervals of 200 operating hours, since the clearance is reduced by wear. The more often the clutch is actuated, the more should this interval be reduced. The clearance of the hydraulically operated clutch is adjusted on slave cylinder. The rest position of the clutch pedal is restricted by a stop. 1 Disconnect return spring on slave cylinder and clutch lever. 2 Push clutch lever upwards until adjusting screw and piston in slave cylinder are in stop position. 3 Measure distance from outer counter nut to clutch lever with slide gauge and record dimension. 4 Keep adjusting screw in this position. Then push clutch lever downwards until throwout bear: ing rests against throwout ring of clutch pressure plate. 5 Measure distance from outer counter nut to clutch pedal once again with slide gauge and record dimension. 6 Deduct measured dimension from position 5 and 3 from each other. The difference is the clutch Fig. 25-2.1/1 clearance and should amount to 3 + 0.5 mm. Cluteh slave cylinder on clutch housing 4 Venting serow 7 If required, adjust clearance by means of adjusting screw. Fig. 25—2/3. 8 Loosen counter nut of adjusting screw. Reduce clearance by screwing adjusting screw outwards or increase clearance by screwing inwards. Tighten counter nut. 9 Attach return spring to slave cylinder and clutch lever.Fig. 25-371 Disassembly and Inspection |. Lift leg spring on throwout ring to release ring, . Unscrew adjusting nut (3 each). . Remove end plate from pressure plate, which will release springs and spring sleeve. Clean all ports, check and replace worn parts 2 wpe mm © Rlerece dimension 227 + 001 mm © 98S 03 mm fnpresed 5. If the foce of the pressure plate shows score marks or burned spots or heat cracks, refinish on lathe or, even better, facegrind. Max. allowance for material removal on pressure pute fs T sn I. Assembly 1. For reassembly proceed vice versa. 2. Tighten adjusting nut until threads are flush. Note: Always use new adjusting nuts for odditional safety.“asimssou9 syjoq Sulusysoy Buyuasco| sayp jaayydy WO} YP}N|D EAOWDY “ “sqiow ypund Aq, sapis yjoq uo nu Buyjsnipo Jo eBuoyy a1n29g * ‘suoueuip jouoBoip SnoUDA U! uIDB0 s2U0 UoISuaWip Bul|salpo ypayp ‘sana] aay a4) Buysnipo sayy :40N) “ese “Big 04 40494 “Jnu Buyisnipo jo suoow Aq. .0,, Uoisuawip Buysnipo oj ena} isnlpy “e Ja2ymAly OF YDIN|D MAIDg "7, “joy “Aj ul ssauypiyy wus °6 Jo Buu Ajquiasso up ‘u8H2q UaAd “10 aod YDINJ2 Mau Jasu) “| ypin]p yo juowysnlpyRemoval, Installation and Venting of Clutch 25-4 System of Single Clutch The clutch system of the hydraulically operated clutch comprises the following components: Clutch master cylinder with reservoir and venting screw. Clutch slave cylinder with venting screw and adjusting screw. Connecting line between clutch master and clutch slave cylinder. ‘Operation of Clutch System: When the clutch pedal is depressed, the piston rod on pedal presses against piston in master cylinder. The pressure established by means of the brake fluid travels through the connecting line in the direction of the slave cylinder and forces the piston with the adjusting screw against the clutch lever which disen- gages the clutch ‘A Removal and Installation 1 Disconnect return spring on slave cylinder and clutch lever. 2 Loosen fastening screws of slave cylinder on console and remove with nuts and snap rings. 3 If required, remove console for slave cylinder. 4 Remove hose from slave cylinder to line on frame and line, as well as fastening clip with shim and rubber insert from frame. 5 Remove hose clip and hose from line toward master cylinder. 6 Remove line from master cylinder. Note: First, place vessel for flowing-out brake fluid in position. 7 Loosen fastening screws of master cylinder on console for clutch pedal in cab and remove to- gether with nuts and snap rings. 8 For installation proceed vice versa. 9 Check all lines and connections for leaks. Replace parts, if required. 10 Adjust clutch clearance. 41. Vent clutch system, B Venting Venting is effected by means of venting screws on master and slave cylinder. The master cylinder must be vented first. 1 Open reservoir screw connection on master \der and add brake fluid up to max. mark, if required. 2 Remove dust cap from venting screw of slave cylinder. 3. Slip venting hose over screw and insert other end of hose into a glass vessel filled up to half with brake fluid. 4 Unscrew venting screw by one or two threads, step down quickly and jerk-like on clutch pedal, but let pedal return slowly. Any enclosed air will escape through venting hose. 5 Keep repeating venting operation until no more: air bubbles are showing up. 6 When stepping down for the last time, keep clutch pedal in its low position until the venting screw is again tightened well. 7 Remove venting hose. Place dust cap on venting screw. 8 Add brake fluid up to max. mark, if required.Fig. 26-0/2 Longitudinal section28 29 30 ‘Shing sieeve ynehronizing #ing rive ting Spring cup Stee ball, f 33 32 at eeeeegee Synchronization Fig. 26-0/3 ‘These vehicles are provided with a transmission in which all gear steps are fully synchronized (synchro- mesh), that is, a special device in transmission serves for smooth and positive meshing of gear wheels by means ot pertinent couplings. Ine shifting ltselt Is cone by means of shifting sleeves, so tat all gear wheels are always in mesh. Table 26—0/1 Gear steps. Reduction Max. speed Gear pairs in km/h constant mesh ' 1: 14.931 713 4 0" 1: 8.292 13.28 4 a 1: 4473 24474 2 v 1: 2.466 44.40 2 v 1: 1.525 72.03 2 vw 14 95.00 0 RI 1: 20.124 5.44 5 Ril 111.096 987 6 ‘The crawler gear unit is provided with two additional forward speeds, for which the crawler gears attached to bottom of transmission housing are added so that two additional crawler speeds are obtained via first and second speed of the normal transmission. Table 26-0/2 Gear steps Reduction Max. speed Gear pairs in km/h constant mesh Crawler speed | 1:46.01 2.08 8 Crawler speed I 1: 25.343 430 8 In addition to versatile knowledge and experience, expert reconditioning of transmission also requires the special tools provided by us, as well as pertinent measuring devices for gear wheels, ball and roller bearings. If this type of equipment is not available, repairs should be made in emergencies only. For all other cases, complete exchange transmissions are available,Il, Power flow in various gears of the main transmission 1st Goor 2nd Geor 3rd Gear 4th Geor Sth Geor 6th Gear 1st Reverse Gear ‘2nd Reverse Geor Fig. 26-0/4Removal and Installation of Transmission (including engine) Refer to removal and installation of engine without tronsmission, Job No. 00-2/1, Item 1 to 13, then 1. Remove front axle. Refer to Job No. 33-1 2. Remove axle drive shaft. Fig. 26-1/1 3. Place assembly stand under front frame end, lower frame, remove hoist 4. Unseraw speadameter coil from trans. mission, 5. Separate electric cables for fuelling unit (Fig. 26-1/2.) Note: Use 2 line connectors for assembly. 6. Unscrew fuel lines from tanks to fuel valve, 7. Attach crank assembly block with special hoisting equipment to hoist and apply slight tension. Fig. 2-1/3 and 26-1/4, Note: If no special hoisting equipment is avoilable, loop chain or wire ropes around crank assembly block. Protect sensitive spots by means of wooden bores. 8. Loosen transmission on rear crank assembly bearings. Note: Observe thickness of washer! As from Chassis No. 404114017177 (Transmission No. 017173) the transmission housing is attached to supporting tube by means of 3 continuous bolts M 16 x 1.5 x 75, 90, 110 long, 3 circlips B 16, 3 hexagon bolts M 16x15. Note: During instollation, align rear crank assembly bearing by pertinent washers in such @ manner that the front crank assembly bearing is in olignment with fastening holes. (Only for transmissions with blind holes on crank assembly mountings.) Fig. 26-1/3 26-1Fig, 26-1/4 10. n 12, 13, 14, 15, Remove cotter pin from pull rod for dif- ferential lock on intermediate lever. Pull out bolt and disconnect pull rod. Remove thrust ball housing of rear axle ‘on transmission. First push back rubber sleeve after loosening hose strap. Fig. 26-1/5. Raise crank assembly block carefully and remove in forward direction. Watch out for drive shaft of rear axle (which is also removed). (o, b, ¢ = points of special importance.) Fig. 26-1/6. Place crank assembly on assembly stand. Note: Provisional placing on wooden wedges is possible, lower carefully. Danger! Front wedge 4 cm, rear wedge 16 cm high For reassembly proceed vice verso. Bleed brakes acc. to Job No. 42-4/1 Fill up with transmission fluid to reach up between the two dipstick marks (SAE 80). Note: Upon installation, engine should swing freely and without distortions together with the exhaust system. By adding shims to the rear crank assembly bearing, the crank assembly must be aligned in such a manner that the rocker in the front engine mount is accurately vertical. As from Chassis No. 40411401 42.82, the new transmissions and exchange trans- missions are provided with the same type of drive shaft for all engines. This shaft differs fram the earlier version by a splining which is 25 mm longer (before 90, now 115 mm}. When installing exchange transmissions in vehicles, prior to the cbove named vehicle number, @ fork lever with offset recess (Part No. 404 25400 08) must be installed, beceuse with increasing wear of the clutch driven plate the inside of the throwout ring presses against the shaft and may prevent complete declutchingReconditoining of Transmission 26-2 |. Disassembly 1. Drain oil 2. Remove transmission cover. . Remove shift plate. 4, Remove guide fork initial stage shoft main shaft. Fig. 26-2/1 5. Remove drive shafts for front and reor oxle (unless already removed when removing transmission from vehicle), 4. Engage front wheel drive and block trans Fig. 2-2/2 mission by engaging two gears. 1 a e701 380 7. Unscrew slotted nut on output flange for front drive after unlocking with socket spanner No. 401 589 00 07 00. 8. Pull flange with puller No. 401 589 01 33 00 Fig. 26-2/2. 9. Remove bearing flange after loosening the two locking countersunk screws M 6. 10, Remove exposed spacer ring on output shaft. Fig. 26-2/3. 11, Remove all hex. screws M 10 on closing cover rear. 12, Remove cover with shaft and pressed-in grooved ball bearing toward the rear. Fig. 26-2/4, 26-2/1 1. Gide fork Fig. 26-2/4Fig. 26-2/5 Fig. 26-2/6 Fig. 26-2/7 13. 14 15, 16. v7, 18. 19, 20. a. 2. Remove shift fork for all-wheel drive. For this purpose, remove locking screw M 6 in shift fork ond pull actuating shaft out of toothing in upward direction. Weich out for top rubber sealing ring, Replace top rubber sealing ring. Remove shift fork and shift rod. Fig. 26-2/5. two slide pieces Remove output gear through transmission opening toward the rear. Fig. 26-2/6. Unlock locking screw on rear axle drive flange ond screw out. Remove locking ring. Pull grooved ball bearing from bearing hub with puller 401 589 00 33 00. Fig. 26-2/7. Remove rear locking ring Unlock locking screw for output flange with socket spanner 401 589 00 07 00. Fig. 26-2/8. Lock main shaft by engaging two gears. Fig. 26-2/823 Remove output flange with puller 401 58901 33.00. Fig. 26-2/9. 24 Unscrew cover of prestage shatt from housing front 25 Unlock exposed hollow screw and unscrew with tool No. 401 689010900. Replace locking plate. Fig. 26—2/10. 26 Unscrew both countersunk screws on outer bearing flange. 27 Remove exposed bearing flange including sealing ring and radial ball bearing 28 Remove transmission input shaft, For this purpose, loosen hex. screws and pull shaft with bearing out of transmission housing 28 Remove main shaft trom housing, Fig. 26-2/11 30 Screw threaded bushing 401 589083300 on prestage shaft. Fig. 26-2/12 31 Push prestage shaft toward the rear by means of fixture 40158901 93.00 and threaded bushing 401 509 00.99 00 until the spacing ring at front and the rear bearing are free. Remove spacing ring. Fig, 26~2/18. 32 Knock large drive gear from shaft by means of plastic hammer and remove. Apply counterhold to shaft. (Wheel is seated on shaft by means of 6 set pins.) Fig. 26-2/14. Fig. 26-2/9 Fig. 26~2/10 Fig. 26-2/11Fig. 26 - 2/12 1+ 401 58008 300 Fig. 26-2/13 Fig. 26-2/14 33. Remove radial ball bearing in transmission housing in forward direction and take-off locking ring. 34 Remove rear locking ring on small bearing out of groove. Fig. 202/19. 35. Slip assembly fork 401 58901 23.00 in front of small radial ball bearing and pull shaft with fix- ture 401 489 01 33.00 and threaded bushing 401 589 08 33.00 forward until drive gear for special pto, intermediate ring and locking ring can be removed together with radial ball bearing. Fig. 26-2116. 36 Remove prestage shatt. Fig. 26-2117. 37 Remove bearing rod. For this purpose, remove locking screw. Remove shift forks 1-4 and 5th speed. Fig. 26-2118. 38 On righthand transmission housing longitudi- nal end, remove oil drip plates with rubber seal and oil pipe after loosening fastening screw with lock- ing nut, Fig. 26-2/1539 To remove countershait, remove cover for tachometer drive with drive pinion for tachometer shaft front, Fig, 26-2/19. 40 Remove locking ring front, 41 Remove exposed spacing ring, 1 mm thick 42. Remove rear cover on transmission housing rear upon removal of remaining hex. screws M 10. 43 Remove exposed spacing washer 44 Knock shaft lightly in forward direction until outer race of front tapered roller bearing is free and can be removed 45 Knock shaft lightly toward the rear until outer race of rear tapered roller bearing can be pushed slightly toward the rear. 46 Remove countershatt. Fig. 26- 20. 47 Remove intermediate gear for front drive, For this purpose and upon removal of the two fastening screws M8 on flange of bearing bolt, remove bear- ing bolt toward the rear and remove intermediate gear in upward direction Fig. 26-216 Puller 4: 509 01 33.09 2 Reverb for 401560 23.09 ae Fig. 26-2/191, Center countershatt 48 After loosening closing plug on transmission housing rear and locking screw on driver, pull- ut shift rod for reverse gear toward the rear. This will free shift fork and driver. Fig, 26-2/21 49 Nemove oil filler pipe, if required (pipe wrench), 50 Force rear bearing outer race out of housing. Refinish front bearing seat of countershatt in trans- mission housing. When outer race is rotating along, the resulting bearing damage may cause damage to bearing seat in housing. 51 Bore bearing seat in housing on boring ma- chine to dimension 77 mm dia. and a depth of 26 mm, Attention! Do not bore completely through seat. 52 _ Insert repair bushing DB-No. 411 264 100 acc. to Fig. 26-2/22. 53 Bore bushing to finish dimension 72 dia. M6 and face front surface. Fig. 26—2/22 54 Machine groove for locking ring. Fig. 26-2122. 55 Clean housing and install shaft, NI. Assembly and Adjustment Note: Two types of housing are available for instal- lation. a) Housing with blind holes for mounting trans- mission at the rear. Standard installation up to chassis No. 404.114-017 176 in accordance with transmission end No. 017 171 Fig. 26-223.b) Transmission with through-holes for mounting transmission at the rear as standard installation starting chassis No. 404.114-017 177 in accor- dance with transmission end No. 017 172. Fig, 26—2/24. Note the two different screw lengths used for Instatlation. 1 Install shift rod, shift fork and driver for reverse gear. Note: Shift fork and driver are locked with snap rings only. Replace formerly installed locking plates with snap rings. Shift fork should point in direction of installation position ot prestage snamt, seal shift rod bore in transmission housing with threaded plug. 2 Insert front axle drive gear with shifting sleeve attached from the rear into housing and into slide pieces. 3 Install shift for all-wheel drive, Note: Make sure of perfect sealing ring on shift crank. When installing shift fork into clamping teeth of shift crank, make particularly sure that in engag- ed position of shift crank (lever resting against transmission housing) the two bores for the slide pieces in the shift fork are visible at output bore rear for approximately half their size. Fig. 26-2125. 4 Locate clamping teeth with hex. screw M 6. 5 Insert slide pieces. Note: Insert upper slide piece with grease to pre: vent dropping-down of sliding piece prior to instal ling shifting sleeve. 6 Place shifting sleeve on front axle drive gear. Note: The wide collar of the shitting sleeve should face large gear wheel. Fig. 26—2/25Fig. 26-2/27 Wee Fig. 26-2/28 7 Install shaft with rear cover and radial ball bearing from the rear. Note: Always use new gasket between cover and housing. Do not forget filter wick and special screw in shat. Fig. 202/26. 8 Check spacing ring for parallel condition, re- place part, if required, and install 8 Install preassembled bearing flange with rubber ring on outside and correct sealing ring (different for front and rear axle) Note: Caution, install red sealing rings only. Do not confuse sealing ring for front axle output, since otherwise transmission oil will flow into front axle. Check iegena! Fig. 26-2/27 and 262/28. 10 Tighten bearing flange by means of the two countersunk screws M 6. 11. Install input flange with tool No. 401 58901 33.00, Note: Make sure that flange shows no burr and that the hole bored into flange is in alignment with bore in shaft, Fig. 26-2129. 12 Insert locking plate and slot pattern with some sealing compound and tighten with socket wrench 401 589.0007 00 and secure. Fig. 26-2/90.13 Check installed front axle power take-off, Disconnect all-wheel drive by means of shift crank, that is, in this position the output flange should stop even though the output gear keeps rotating 14 Install intermediate gear for front power take- off with shaft and tighten. 18 Introduce counter shaft completely preas- sembled without bearing rings and with tachometer pinion first into housing and install. Watch out for shifting sleeve front. Flange should face tachometer pinion. Fig. 26-2/31. 1 Force-in tront bearing outer race witn Hollow Drift 401 589 05 61 00. Insert spacing ring and lock- 9 ring, Fig. 26-2/32 Note: Spacing ring front constant 1 mm. 17 Push counter shaft completely forward by means of nollow arift and force-in rear bearing outer race with Hollow Drift 401 589 06 61 00. Fig. 26-2/33. 18 Measure distance between bearing outer race, tapered roller bearing rear and transmission hous- ing rear wall with depth gauge. Permissible end play of counter shaft 0.25 + 0.1 Fig. 26-2/30 mm. Make up for difference with pertinent com- pensating washer. Fig. 26—2/34. Fig. 26-2/31 Fig. 26—2/33Fig. 26-2/95 Fig. 26—2/38 19 Screw-on rear end cover. Note: Coat all fastening screws and cover with sealing compound. 20 Mount front cover for counter shaft with drive gear for tachometer, No! Use new yesket! 21 Mount oil pipe, oll drip plate and rubber seal to right-hand housing wall 26-2/35, 22. Install bearing rod and shift forks 1, 2, 3, 4 and Sth speed. Note: Shift rods should operate smoothly. Fig. 26-2/18, 23 Install preassembled pre-stage shaft into housing. Fig, 26-2117. 24 Slip radial ball bearing, spacing ring, locking ring and drive gear for special pto rear on pre-stage shaft. Locking ring should be seated well in groove. Note: Make sure that the rear bearing has no clearance. This is done by inserting spacing rings of varying rings in-between radial ball bearing and locking ring, However, always use one spacing ring only. Spac- ing rings are available 2.3 mm, 2.4 mm, 25 mm, 2.6 mm, 27 mm, 28 mm, 3.0 mm, 3.1 mm, 3.2 mm and 3.3 mm thick, depending on requirements during installation. 25. Slip pre-stage shaft to rear and position drive gear. 26 Apply Too! No. 401 58901 33 00 and threaded bushing 401 589083300 to pull pre-stage shaft forward until drive gear is completely seated on set pins and rear radial ball bearing in bearing eye. Fig. 26—2/36 27 Insert spacing ring and locking ring front and force-in front bearing by means of Hollow Drive 401 589 15 61 00. Fig. 26-237.28 Insert locking plate. Tighten hollow screw with Tool No. 401 589.01 0900 and lock. Fig. 26—2/38. 29° Screw down cover for pre-stage shaft together with sealing ring, 30 Insert preassembled main shaft 31 Install preassembled transmission input shaft Fig. 262/42. 32. Insert preassembled rear bearing flange and screw down with two counter-sunk screws M 6. Do not forget paper gasket. 33 Mount input flange rear by means of Fixture 401 589 01 33 00. Note: Oil bores of flange and 6th gear wheel should be in alignment Fig. 26-2/99. 34 Insert locking plate, tighten slot nut with Socket Wrench 401 589 00 07 00. 35 Install locking ring for ball bearing in output flange 36 Insert bearing hub in cylindrical pin of main shaft. 37 Force-in ball bearing with Hollow Drift 401 589 1461 00 and install 2nd locking ring into output flange. Fig, 262/40. Note: install bearing nub with required flange thickness as required. The following sizes are available: 2.0 mm, 2.2 mm, 2.3 mm, 2.4 mm, 25 mm, 2.6 mm, 2.8 mm, 3.0 mm, 3.2 mm and 3.4 mm. Fig. 26-2141 Fig, 26-2/98 Fig. 26-2/39 Fig. 26—2/37 Fig. 26—2/40Fig. 26—2/43 1 Guide fork Note: The play of the synchronizing ring between input shaft and main shaft should be 0.6 to 1.0 mm. This play is set by installing a pertinent compensat- ing washer. However, always install one washer only. Fig. 26-2142, 38 Attach bearing hub rear on main shaft with washer, locking plate and hex. screw. Note: Tightening torque 14—16 mkp. 39 Lock hex. screw. 40 Loosely insert guide fork between shitting sleeve pre-stage and shifting sleeve main shatt Fig, 26-2143. 41 Install shift plate with the following positions of the shift tongues: Shift tongue tst—4th speed idle position Sift longue Stl speed idle position Shift tongue 6th speed idle position Shift tongue pre-stage pre-stage on Shift tongue “forwards” ~ “reverse’ engaged “forward” Set shifting sleeve in transmission accordingly. With the shift plate correctly seated in transmission, the plate should have 2-3 mm clearance in circum- ference of fastening bolts, 42. Mount transmission cover and screw down. Note: Make sure that the reverse lever is set to “forward” and that the shift finger is inserted in slot guide of shift plate. The shift lever for special pto (if installed) should be set to “on" and the shift gear for the special pto on pre-stage shaft should be pushed completely forward. 43 Screw-on special pto or crawler gear auxiliary unit (if installed). 44 Fill-in transmission oil only when vehicle is completely assembled (SAE 60). 45 Install transmission into vehicle.Transmission Cover 26-3 Section 4-B \ 9 1 ji : | 54 A655 wo Ls 4 7 1 AB ck | LI i Fig. 26-3/1 Wy iolica dea 7. Check all parts and replace, if required. 38 Searels keh 1 SSH tong ‘ 12 Shit Rvsing sopport 8, For installation proceed vice verso, making & Spocer sleeve 14 losing ring, 2900 sure that the reversing lever is set on 3 Shino finger TSE Sia eps tor mera “forward” and the shifting finger is inserted . Remove inside engine panels. |. Removal and Installation Remove driver and co-driver seat. Remove panelling of lever system and screw off floor plate between lever system and engine panelling inside Remove cotter from pull rod for actuating hand brake on bowden wire connection and take out. |. Remove cotter pin on shift linkage for front axle drive and differential lock rear and disconnect. Unscrew support of hand lever assembly and remove together with lever for four- wheel drive and hond brake lever. 3. Unscrew transmission cover and remove. Fig. 26-3/2. in slot guide of shift plate. The shift lever for pio drive should be set to “On”, if installed, and the slide gear for the special pto should be pushed completely forward on pre-stage shaft, 9. Check gear shift upon installation. a Fig. 26-3/2Fig. 26-3/3 2 Sei 3 Shit Inger Fig. 26-3/4 4 Ror cover Clamping wosher Spacer sess Srp Sina fina Fig. 26-315 Aan Il, Disassembly and Assembly ‘A. Main Shift Lever with Bearings 1. Remove rubber cap from shift housing. 2. Unscrew hex screw in shift lever bearings and remave together with circlip. Fig. 26-3/3. 3. Remove main shift lever in lateral direction 4, Remove shifting finger in upward direction. 5. Unscrew rear cover from shift housing. 6. Unscrew hex bolt and remove clamping washer. 7. Remove cyl. notch pin and remove bearing tube. 8, Move shaft forward until shifting finger ‘abuts. Move shaft further ahead with light blows until the two halves of the locking ring in front of the shifting finger become loose and can be removed. Fig. 26-3/4. 9. Unscrew the 3 hex bolts on shift housing support and remove together with shift housing, 10. Push shift housing toward the rear until the two halves of the locking ring can be removed Fig. 26-3/5. 11. Remove shift housing from housing support 12. Replace rubber seal Fig. 26-3/6. 18. Remove geor shifting shaft in forward direction, which will release the shifting finger. B. Shift Lever for Reverse Gear 14, Loosen the two hex bolts and remove shift lever for reverse gear together with cover.15, Unscrew hex nut on transmission cover from outside, Fig. 26-3/7. 27. Replace breather screw on transmission Fig. 26-3/10. 16. Remove fork lever together with fitted screw in inword direction. Installation Note: The fitted screw is protected against turning by means of @ cyl. notch pin Grease fitted screw during instellation. Fig, 26-3) 28. Check all parts for weor and replace damaged parts 29. For reassembly proceed vice versa. C. Shift Tongue and Shift Lever for Special Pto 17. At rear shifting tongue, compress spring by pressing against spring retainer ond remove 2-part locking ring, 18. Remove spring retainer. 19. Remove spring. 20. Remove roller guide cover. 21. Remove cyl. rollers, two each. Fig. 26-3/8 Fig. 26-3)9, 22. If required, nock rivet out of spring bolt and remove guide piece. 23. Remove spring bolt. 24, IF required, punchmerk rivet on shifting tongue front and drill. Knock rivet out with mandrel 25. Remove guide piece and shifting tongue 26. Loosen both hex bolts and remove lever together with bearing, Note: No further disassembly is required If a component should break, replace entire lever with bearing ond shifting finger. Fig. 26-3/9 Fig. 2-3/7 Fig. 26-3)10Shift Plate |, Removal of Shift Plate 1. Remove shift plate. 2. Check removed shift plate for wear and replace defective parts, install new shift plate (exchonae plate) if required, Note: Wash new shift plate thoroughly with nitro solvent to remove preserving com- pound; then lubricate, 3. Installation is best at the following shifting sleeve positions, Fig. 26-41 st, 3rd and 2nd, 4th geor: shifting sleeve ‘on main shoft = idling position Sth gear: shifting sleeve on countershaft = idling position 6th gear: shiffing sleeve on main shaft idling posi Pre-stoge shift: shifting sleeve on main shaft = completely disengaged (stop agoinst fixed wheel) Shifting sleeve on pre-stoge shaft = engaged that is, accurately under above named sliding sleeve in olignment. The loose shifting claw between the main ond pre- stoge shaft must be installed. Forward and Reverse Gear: Follower of shift rod = forward gear engaged Special Pro Slide gear on pre-stage shaft = engaged that is, slide gear on bearing bracket against stop. 4, Set shifting tongues of shift plate ‘eccordingly Shifting tongue Ist, 2nd, 3rd and 4th gear = idling position Shifting tongue Sth and 6th gear = idling position Shifting tongue = Pre-stage shaft engaged (toward the rear) Shifting tongue forward and reverse gea forward geor engaged (in forward direction) 5. Insert shift plate. Fig. 26-4/3. Fig. 26-4/210. inning of Shift Plate . Exchange Bell Crank Lever . Release punchmarks. Unscrew hex nut on bottom of shift plate and remove resilient serrated washer. Remove cam bolt and bell crank lever. 3. Check cam bolt. Cam should be eccentric by 2 mm, Check bell crank lever for distortion. The angle should be 115° + 15. |. Disengage pre-stage on shift plate. The rolls of the shifting tongues should be securely in the cut-in locks. For positions of shifting tongue refer to Fig. 26-4/2. . Disengage locking bolt for shift slide plate. Clomp shift plate carefully into vise. Insert crank bell lever with straight finger into shift slide plate and install cam bolt including the resilient serrated washer ond nut. Tighten nut on threads of com bolt to the extent that the cam bolt can just be turned manually at its hexagon hecd. Place head of offset crank bell lever finger ‘against follower. Fig. 2-4/4 i. 12 13. 14, 15. 16. V7. 18, 19. Turn crank bell lever in direction of arrow until the shift slide plate has attained its end position by moving forward in direc- tion of arrow. Note: The drive gear for the pto drive is actuated by the shifting tongue on the transmission cover. Check whether shifting clow is correctly seated between pre-stages and main shaft With the shift plote properly seated, a play of 2-3mm should be available within range of fastening bolts The engagement of the shifting tongue can also be checked by means of rod-type or tubular lamp inserted through the round ‘or square hole of the shift plate Prior to mounting the trans pour some transmission oil paris of shift plate. ion cover, ‘on moving The follower should now be able to move bell crank lever freely, with the air gap between the bell crank lever head and the edge on the follower amounting to ‘approx. 0.5 mm. Fig. 26-4/4. When the bell crank lever head knocks ‘against the edge of the follower or when the gap is too large, correct by turning cam bolt, as required. Reengage locking bolt. In this position, there should still be o noticeable play in the longitudinal move- ment of the shift slide plate between the bell crank lever head of the bell crank and the pin of the locking bolt. IF not, the edge on the follower must be slightly refinished Also make sure that the bell crank lever moves freely after 25 mm travel. Fig. 26-4/4, dimension b, Upon completion of the above steps, tighten nut on cam bolt, making sure that the bolt does not turn along. For this reason, hold cam bolt head in position with open end spanner. Secure hex nut and bolt by means of two punchmarks against loosening.Fig. 26-4/5 Installed at Shifting tongue of pre-stage shaft Shifting tongue for 5th and 6th gear Stifting tongue Ist, 2nd, 3rd, 4th gear Shifting tongue for reverse gear Fig. 26-4/6 Fig. 26-4/7 Fig. 26-4/8 Spring length mm v 9 2 2 B. Replacing Coil Spring of Detent 20. Compress coil spring by pressing against spring retainer and remove 2-part safety ring Fig. 26-4): 21, Remove spring retainer. 22. Remove spring. Caution! The four springs are of different length and therefore clso of different pressure. Refer to table Fig. 26-4/6. C. Replacement of Shifting Tongues 23. Remove coil spring of pertinent detent. 24, Remove roller guide cover. 25. Remove cyl. rollers. Fig. 26-4/7, 26. Punchmork and drill spring bolts and rivets of pertinent shifting tongue on bottom of shift plate. Knock out spring bolts and rivets with punch and remove shifting tongues including guide pieces end folle wers. Fig. 26-4/8, Always use new rivets and spring D. Complete Replacement of Guide Rails for Shift Slide Plate Note: Guide rails are removed only when shift plate Is removed, 27. Remove all ports described under item 1 to 27. 28, Remove cotter pin from locking bolt, remove washer and locking bolt. Fig. 26-4/4 29. Remove shift slide plote from guide rails. 30. Carefully remove rivets from guide rails including detent spring 31. Check all parts for wear and replace de- fective parts 32. For reassembly proceed vice verso.Disassembly and Reassembly of Main Shaft 1. Wash and clean main shaft. 2. Remove front synchronizing ring. 3. Remove shifting sleeve front (before 5th gear wheel). This will release the 3 follow- ers including balls end spring cups (bright spring housing}. 4, Remove output gear with shifting sleeve. Fig. 26-5)1. Note: Be sure that no rollers of cylindrical roller becring are lost 5. Remove rollers from roller cage, remove cage. 6. Remove synchronizing ring. 7. Remove synchronizing sliding sleeve from ‘output gear. This will release three follow- ers, including balls and spring cups (black spring housing). 8 Clamp main shaft into vise, heat syn- chronizing cone and pull off with tool No. 000 589 89 33 00. Fig. 26-5/2. 9. Turn main shaft cround in vise, 10. Remove locking ring and thrust ring. 11. Remove roller eage with rollers. 12. Remove locking ring in front of 5th gear wheel. 13, Pull off geor wheel for 5th gear ond remove key. Fig. 26-5/3 Fig. 26-5/1 Fig. 26-5/2 Fig. 26-5/3 26-5Fig. 26-5/4 Fig. 26-5/5 14, 15. 16. v7, 18, 19. 20. a. 2, 23. 24, 25. 26. For reassembly proceed vice versa. Clamp main shaft into vise. Insert key and install 5th geor wheel with Installation Sleeve No. 401 589 11 61 00. Install locking ring in front of 5th gear wheel. Insert cylindrical rollers (10 each) with grease in cage and slide on main shaft Note: Do not use rollers with + tolerances. Fit thrust ring and insert locking ring. Turn main shaft in vise around. Heat syn- chronizing cone to 180°-200°C and mount quickly. Insert the three followers with balls and spring cups (black housing) on output gear and position shift sleeve in such a manner that the three flats of the internal toothing are each located at the ball center of a follower. Note: The wide flange of the shifting sleeve should face the output gear. Fig. 26-5/4. Slide on synchronizing ring. Position roller cage and insert cyl. rollers (17 each) with grease. Slide on output gear. Note: Watch out for uniform tolerance group. If the refitted output gear runs heavily ar has tna much play, exchange rollers against those of a thinner or thicker tolerance group. The three tolerance groups are 0.-2u and ~4u, When using new parts, be sure that the cage is behind edge of shaft, so that the output gear cannot collide. Insert main shaft vertically from above into output gear. Fig. 26-5/5, Position the three followers with balls and spring cups (bright housing) on 5th gear wheel and fit shifting sleeve in such o manner that the wide collar faces the Sth gear wheel. Insert front synchronizing ring.Disassembly and Reassembly of Pre-Stage Shaft 1. Wash and cleon pre-stage shaft 2. Remove shifting sleeve in forward direc- tion. This will release the three followers with balls and spring cups (blank housing). Note: The wide flange of the shifting sleeve should face toward the front (in driving direction) during reassembly, Fig. 26-6/1. 3. Remove shift gear for reverse speed. 4, Remove thrust washer. Note: Install thrust washer with Installation Sleeve No, 401 589 01 39 00. Fig. 26-6/2. 5. Pull off sl ing sleeve. 6. Remove synchronizing ring Note: The play between the synchronizing ring and the follower should be 1.0 mm. 7. Replace set pins in pre-stage shaft front Note: When inserting the six set pins the slots should face in direction of rotation and the bevelled end forward. Fig. 26-6/3. 8. Check all parts for wear and replace those which are defective. 9. For reassembly proceed vice verso. Fig. 26-6/1 26-6 Fig, 26-6/2 Eres Fig. 26 6/3 1 wrong 2 tightDisassembly and Assembly of Counter Shaft 26-7 Fig. 26-7/1 Up to the end of 1970, the spring cups installed In drivers of shifting sleeves for tst to 4th speed and Sth speed were black. Since early 1971, the spring cups installed in driver of shifting sleeve for tst to 4th speed are blank, and the spring cups in driver for Sth speed are yellow. 1 Clamp counter shaft with 1st and 3rd gear wheel into vice and block shaft with shifting sleeve for Ist and 3rd speed. 2. Clean bore in output pinion for tachometer with twist drill 11. mm dia. from oil residue. 3 Pull pin of Tool 401 589 11 33.00 out of clamp- sleeve and force clamping sleeve into drive pinion, so that the pinion front edge is approx. 5 mm away from threads of clamping sleeve. Fig. 26-7/2. 4 Slip supporting bushing over clamping sleeve, ‘screw-on hex. nut with washer and tighten slowly. ‘Apply counter hold to clamping sleeve end. Fig. 26-7/3. 5 Press pin into clamping sleeve until the knurled head projects still approx. 10 mm. The clamping sleeve will then expand and grip behind pinion end, 6 Clamp pulled out pinion into vise, knock out set pin, compress the expanded clamping sleeve with remover included in Too! 401589113300 and take out of pinion. Fig. 26-714, hig. 26/47 Unlock slot nut and screw out with Slot Nut Wrench 406 589 02 07 00. Fig. 26-7/5. 8 Remove locking plate and washer. 9 Pull off shifting sleeve. This will free the three drivers with balls and spring cups. 10 Apply a three-legged puller to pull the driving ring for 5th gear wheel including spacing sleeve and tapered roller bearing. Counter-sink an appro- priate hex. screw with a drill in its center for use as a support for the puller and insert into bore of counter shaft. Fig. 26-7/6. 41 Remove the two keys from counter shaft Fig. 26-7/5 Fig. 26-7/6 Fig. 26~ 12 Clamp counter shaft vertically into vise and completely pull off the wheel block still remaining ‘on shaft by means of Puller 000 589 89 33.00 and extended Legs 00 589 90 33 00. Fig. 26—7/7. 13 Cut bushing of 1st and 3rd gear with a chisel, if required, and remove. 14. Pull-off tapered roller bearing at shaft end, 15. Drill closing plug out of counter shatt rear for cleaning oil bores in shaft, if required, and replace. 16 Check all parts for wear and replace defective parts. 17 For assembly proceed vice versa. 18 Clamp counter shaft vertically into vise.20. a 23 24, 25. 26. 77. Install Ist and 3rd gear wheel with shifting teeth up. Note: The radial play between the bushing and the Ist/3rd gear wheel should be 0.13 to 0.19 mm. The oxicl ploy is approx 0.3 mm (bushing should project Insert synchronizing ring into 3rd geor wheel. Note: The dimension from upper edge of synchronizing ring to upper edge Ist and 3rd gear wheel should not exceed 8.2 mm. Fig. 26-7/8. Insert the two keys. Force in follower ring for Ist to 4th gear with Installation Sleeve 401 589 11 61 00. Fig. 2-7/9, Note: The teeth of the follower ring are each thicker in the center on one end. This thicker area should face toward the right, seen in driving direction, when installed. Insert follower with bolls ond spring cups (black housing) and install 9 sleeve for Ist to 4th gear. Note: These three followers are the only ones in the transmission which are of rectangular shope. Install bushing for 2nd and 4th geor by means of Installing Sleeve 401 589 11 61 00. Remove burr, if ony. Fig. 26-7/10. Insert synchronizing ring in 2nd/4th gear wheel. Note: The dimension from top edae of synchronizing ring to top edge of gear wheel should not exceed 8.2 mm. Fig. 26-7/8. Install synchronizing ring and gear whee! for 2nd and 4th gear. Note: Bushing should project approx. 0.30 mm. Fig. 26-7/9 Fig. 26-7/11427016 28 Fig. 26-7/12 P24] Fig. 26-7/13 34200 52¢____—_+| Fig. 26-7/14 Fig. 26-7/15 28, 31. 32, 33, Position thrust ring. Install bushing for 5th ond reverse gear by means of Installation Sleeve 401 589 11 61 00. Install 5th and reverse gear wheel. Fig. 26-7/11. Note: Bushing should project approx. 0.30 mm. Insert the two keys. Insert synchronizing ring for Sth gear wheel. Install follower ring for 5th gear wheel by means of Installation Sleeve 401 589 11 61 00 in such a manner thot the Projecting hub points downward. Note: The follower ring should project lightly opposite the shaft step. Insert the three followers with balls and spring cups (black housing] and position sliding sleeve with wide flange up in such ‘a monner that the three Flats of the inter- nal teething are each oligned to the ball center of the followers. Install spocer sleeve. Old version of spacer sleeve. Fig. 26-7/12. Pertinent countershaft Fig. 26-7/13. Note: If the countershaff of the old version is exchanged against a countershaft of the new version, also install a spacer sleeve of the new version. The spacer sleeve should project slightly across the front shoft step. If the countershaft need not be replaced and if a spacer sleeve with the four recesses is sill installed, replace by version shown in Fig. 26-7/12. New version of spacer sleeve Fig. 26-8/14, Pertinent countershaft Fig. 26-7/15. Install front tapered roller bearing by means of Installation Sleeve 401 589 12.61 00.wu £0-€°Z Paloid pynoys uo!Uld ‘uoluid ay) Jo pod Bu sad ay jo uo!suawip 24) Buppays Aq emo} 04 ‘painspau aq 4s1yy pjnoys 4ap|noys oy dn yidap ploy ey) uosoa siq 10) uo yoyss9juno> Jo sepjnoys oj da payiosut ‘UJ “U! 2210) puD uoLU 1 JO PAOW YOUS YILAA, :910N Jo0219pun ‘paj)ok “saewopeeds 104 uoluid eatsp ul 22104 “LUL9 4 “00 19 70 685 Lov 2A99|§ UoH40}}0)Su Jo suDsW Aq Buupaq sajj01 pasedoy 4001 |j0)5u) sdyu g[-gxow enbsoy Buruaiy6ry 9UL9 Bl “21n295 puo 00 £0 $0 685 LOY Jeuuods ulg YIM ynu percouB uayyBry + “42Ysom po] pu WHYS UNOW. cs “Disassembly and Assembly of Drive Shaft 1. Remove bearing cover and seal from bearing flange. Fig. 26-8/1. Note: Always use new seal 2. Clamp drive shaft into vise and unlock grooved nut in bearing flonge. Note: Always insert new locking washer during assembly. 3. Unscrew grooved nut with Pipe Spanner 401 589 07 07 00. Fig. 26-8/2. 4. Force drive shaft out of bearing flange. 5. Remove locking ring on grooved ball bearing from bearing flonge. 6. Pull grooved ball bearing out of bearing flange. Note: Force in grooved ball bearina during assembly by mecns of Installation Sleeve 401 589 05 61 00. Fig, 26-8/3. 7. Check all parts for wear and replace those which are defective. 8, For reassembly proceed vice versa Fig. 26-8/1 Fig. 26-8/2 | sci . Fig. 26-8/3Disassembly and Reassembly of Bearing Flange for Axle Di Remove sealing ring from bearing flange. Remove two locking rings from bearing flange. 3. Remove oil feed ring, 4, Force out grooved ball bearing. 10. n. . Check all parts for wear and replace those which are defectiv For reassembly proceed vice verso. Insert locking ring. . Position bearing flange on Fixture 401 589 00 31 00. Force in grooved bell bearing using Installation Sleeve of Fixture 401 589 00 31 00. Fig, 26-9/1. jeed ring. Insert locking ring. Insert Position sealing ring ond force in Fig. 26-9/2. Note: Sealing rings have a spiral grinding pattern ond are therefore different for front and rear axle drive. Sealing rings may not be interchanged and are there- fore identified on cage. Shaft sealing ring for front axle drive DB No. 99.2990.1008-00. ight-hand spiral. Fig. 26-9/3. Shaft sealing ring for rear oxle drive DB No. 99.2990-1009-00. Left-hand spiral. Fig. 26-9/30 Fig. 26-9/3as[6-90 S14 M9198 MO|JOY jo suoow Aq Bnd jay ur moss voy “da SMOYS SPDALUI-O|-W 94! JO poa4s BuO \yUA OUS OLU! [0 YI! pexDOs Bnjd joy mou pasu| -Z io passoidwioo) |jem 2j04 pelqlup uoa|a “Dip wu gg ||up Yilm Bid 49} BAID9JOP SAOWOY “MAIS MO|JOY eACWOY “| ‘ojd 9x0 ju 404 YOYS U! Bnjd 4Ja4 e20/da1 Osj0 ‘par0jdai st ‘oid 9)xo ju04y ay) UO Buy Buyjoas 0 atay 4203 1910N, vl6-9% B14 Juoyy 24) Wosy uses @Buoy ay} 0 s19j01 skomjo sBuls Buljoas y UO pajoripul uoKDIO! Jo UOIDaNIP sy *sBuys Buyoes pas ysujo8o 4nojo2 sayjouD eAcy YY sBulr BuyjDes jo aopjdes ‘s1odes uorssiusunsy Jo 4uaAe 94} U} “Mou wos} so paljoisut aq Xow sBum Guyjpos par duo ioys 240N pai — aya — aniq — pojq ‘eouanbas u! peljojsu! e10m sinojo> p09 Bulo}joj ays yitm SBULs Buljoas ‘AjsoW0y sl6-92 “614 16-92 “B14Special Take-off for PTO Shafts 1. Removal and Installation 1, Unflange special take-off on transmission housing, Fig. 26-10/1 2. Remove gaskets ond sealing rings. 3. Clean sealing surfaces well. 4, Coat new gasket on both sides with sealing compound. Always use new seals and sealing rings. 5. Screw take-off to transmission housing. Note: During installation, be sure that the hexagon bolts, which ore of different length, are entering the correct screw hole. Insert screws and set pins according to Fig. 26-10/2 special Il, Disassembly and Assembly A. Intermediate Shaft 1. Unlock grooved nut of intermediate shoft and unscrew with Pin Spanner 401 589.0507 00. Ramave lnck washer Fig. 26-10/3, 2. Remove locking ring on shaft reor. Fig. 26-10/4. 3. Remove locking ring from seat behind drive geor (in shaft center) and leave loosely on shaft. Fig. 26-10) 4. Force intermediate shaft from the rear toward tho front until tho drive gear on the rear shaft end can be removed, as well as the grooved ball bearing at the shoft front. 26-10 Fig. 26-10/2 a os 1 3mm fer nd rrew 2im 5 Ban 3 am Fig. 26-10/3 Fig. 26-10/1 Fig. 26-10/45. Remove locking ring behind drive gear (locking ring pliers). Fig. 26-10/6. 6. Force intermediate shaft out toward the reor. Watch out for the two locking rings in shaft center, which should be lifted from the groove in each case. 7. Remove drive gear, spacing tube, locking rings and shaft together with topered ball bearing. 8. Remove locking ring from rear bearing boss. Fig. 26-10/5 9. Remove topered ball bearing and locking rings from shaft. Take keys out of shaft B. Output Shaft Fig. 26-10/7. 10. Remove cotter pins on both sides from cosile nut and unscrew, remove together with washer. 11. Pull off both output flanges. (Conventional puller.) 12. Unscrew cover on both sides and remove with sealing ring front or seal and fitted washer rear. Note: Always place new sealing rings Fig. 26-10}6 under hexagon bolts, 13, Force output shaft out toward the rear. This will free the rear grooved ball bearing and the spacer ring for removal 14, Remove output gear. 15, Remove shaft and key. 16. If required, unscrew the two studs in shaft and replace. 17. Force front grooved ball bearing out of =, o housing oo : 18. Check all parts for wear and replace those won which are defective. Fig. 26-10/7 19. For reassembly proceed vice verso.Fig. 26-11/5 Fig. 26-116 C. Shaft with Intermediate Gear Block (Shaft Ill, refer to Fig. 26-11/1) 14, Remove set pin 15. Screw hexagon bolts into face end of shaft Ill and pull out shaft. Fig. 26-11/5. 16. Remove intermediate gear block, compen- sating washer end sealing ring in housing. 17. Remove locking rings from bearing bushing cond thrust washer 18. Remove bearing bushing, needle bearing with spacer bushing from intermediate gear block D. Gear Shifting Shaft 19. Remove set pin from gear shifting shaft. 20. Unscrew closing screw with sealing ring from other shufl end, 21, Screw hex. bolt M 10 into shaft and pull out shaft, Fig. 26-11/6. Note: For this purpose, turn shaft by means of screw to the right by 90° and push into housing. This will free the locking ball and spring on shifting claw for removal. Note: During installation, and prior to unscrewing hexagon bolt from shaft, knock down set pin which keeps the shaft from turning, 22. Remove shifting claw. Fig. 26-11/7. 23. Check all parts for wear and replace those which are defective, 24, For reassembly proceed vice verso. Fig. 26-11/7