Dissassembly, Assembly and Measurement of Gear Set

DISASSEMBLY, ASSEMBLY AND MEASUREMENT OF GEAR SET

Special Tool:

Disassembly and Assembly








NOTE: One-way clutch 1st version "A" has two friction bearings (11a and 11b) for one-way clutch inner race (13). On this version the one-way clutch outer race (24) is peened to inner plate carrier K2 (19) (arrow). Starting transmission end No. 169754 the one-way clutch 2nd version "B" is installed with one friction bearing (11a) only. The one-way clutch outer race is not permanently connected to inner plate carrier. Assembly procedure for both versions is the same.

Installation Note
Lubricate bearing points and slide surfaces during assembly.





1 Clamp assembly fixture 126 589 00 35 00 at the two surfaces into vise with disk facing in upward direction. Place gear set into assembly fixture.
2 Remove circlip (3).

Installation Note
Upon insertion, push circlip into groove by means of a screwdriver, after the front gear set has been mounted.

3 Lift off front planetary gear set (2).





4 Remove axial bearing (4) and input shaft (1).

Installation Note
Upon insertion of input shaft (1), mount axial bearing (4).





5 Remove radial bearing (5) and axial bearing (6).
6 Remove output shaft (8).

Installation Note
Upon insertion of output shaft (8), insert radial bearing (5) and axial bearing (6).





7 Remove axial bearing (9) and pull out sun gear (10).

Installation Note
Insert sun gear (10) into one-way clutch and rotate, one-way clutch should lock in direction of arrow, then place axial bearing (9) on sun gear.





8 Remove circlip (21).

Installation Note
Push circlip into groove by means of screwdriver.

9 Lift inside plate carrier K2 (19) with one-way roller clutch out of connecting carrier (7).





10 Lift off supporting disk (11).

Installation Note
Mount supporting disk (11) in such a manner that the lug centers bore in one-way clutch outer race (arrows).

11 Remove compensating ring (17) and O-ring (12).
12 Rotate inner race (13) of one-way clutch in anticlockwise direction and pull out.
13 Remove cylindrical rollers.





14 Place thrust washer (18) into inner plate carrier (19).





15 Insert cylindrical rollers (16) into roller cage (14).





16 Place one-way clutch outer race (24) on inner plate carrier and insert roller cage (14).





17 Press cylindrical rollers (18) against compression springs (15) and insert locking plates (085) with offset in outward direction.





18 Insert oneway clutch inner ring (13) while rotating in direction of arrow, then remove locking plates (085) (refer to Fig. item 17).





19 Place compensating washers (22) into connecting carrier (7).
20 Hold one way clutch together and place into connecting carrier.


Measuring





21 Check end play of one-way clutch and compensate.

Check clearance between one-way clutch and connecting carrier by means of a slip gauge.

Compensate clearance to 0.05 - 0.2 mm by means of compensating washers (22), then insert O-rings (12) and (20) (Fig. item 11 and 14).





22 Lift gear set out of assembly stand and push axial bearing (23) onto drive shaft.