Dismantling, assembling and measuring gear set - RA27037220660X(27-660)

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Operation number of the operation texts and work units or standard texts and flat rates:

27-4510

Fig 1: Exploded View Of Gear Set Component

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Lubricating thrust ring (99)	Remove. When installing, insert with grease (item 1).
Gear set, complete	Clamp in assembly bracket 126 589 00 35 00 with output shaft (item 2).
Snap ring (3)	Remove, install using screwdriver (item 3).
Front planetary gear set (2)	Take off together with axial bearing (23) (items 4 and 5).
Axial bearing (4) and drive shaft (1)	Remove (item 6).
Output shaft (8)	Remove together with radial bearing (5) and axial bearing (6) (items 7 and 8).
Axial bearing (9) and sun gear (10)	Remove, install (item 9).
Snap ring (21)	Remove, install using screwdriver (item 10).
Inside disc carrier K2 (19) with free-wheeling unit	Remove from and insert into connector (7) complete. After assembly, adjust axial play between free-wheeling unit and connector to 0.05 - 0.2 mm (items 19 - 22).
Support disc (11)	Lift off. When fitting, the lugs must engage in the bore in the outside ring of the free-wheeling unit (item 12).
Shim ring (17) and O-ring (12)	Remove, install (item 13).
Inside ring of free-wheeling unit (13)	Remove and install in counter-clockwise direction. Refer to item 14 for installation note.
Cylinder rollers (16) and roller cage (14) with compression springs (15)	Remove, install, check (items 15 - 16).
Outside ring of free-wheeling unit (24)	Remove, install, check (item 17).
Friction ring (18) and O-ring (20)	Check (item 18).

Special tool

Fig 2: Identifying Special Tool (126 589 00 35 00)

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AUXILIARY TOOL (SPARE PART)

Retaining plates (16 plates)

126 277 00 73

NOTE: Lubricate bearings and sliding surfaces when assembling.

Dismantling and assembling

Remove lubricating thrust ring (99) from drive shaft.
Installation note

Insert lubricating thrust ring into groove with grease in such a way that the diagonal cut remains closed.
Clamp assembly bracket 126 589 00 35 00 into vice by the two flat surfaces and with the plate uppermost. Position gear set in assembly bracket, output shaft first.

Fig 3: Identifying Snap Ring
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Remove snap ring (3).
Installation note

After inserting, push snap ring into groove using a screwdriver after the front gear set has been fitted.

Fig 4: Identifying Snap Ring
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Lift off front planetary gear set (2).
Remove axial bearing (23) from planetary gear set and check.

Fig 5: Identifying Axial Bearing From Planetary Gear Set
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Take off axial bearing (4) and drive shaft (1).

Fig 6: Identifying Axial Bearing, Drive Shaft
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Remove radial bearing (5) and axial bearing (6).
Take out output shaft (8).

Fig 7: Identifying Radial Bearing, Axial Bearing
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Remove axial bearing (9) and pull out sun gear (10).
Installation note

Insert sun gear (10) into free-wheeling unit and rotate; the free-wheeling unit must lock in the direction of the arrow. Then place axial bearing (9) onto sun gear.

Fig 8: Identifying Axial Bearing, Out Sun Gear
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Turn connector and take out snap ring (21).
Installation note

Press snap ring into groove using a screwdriver.
Lift inside disc carrier K2 (19) with freewheeling unit out of connector (7).

Fig 9: Identifying Lift Inside Disc Carrier K2, Freewheeling Unit Out Of Connector
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Lift off support disc (11).
Installation note

Position support disc (11) so that the lug engages in the bore in the outside ring of the freewheeling unit (arrows).
Remove shim ring (17) and O-ring (12).

Fig 10: Identifying Shim Ring And O-Ring
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Turn inside ring of free-wheeling unit (13) in direction of arrow and pull out.

Fig 11: Identifying Ring Of Free-Wheeling Unit
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Installation note
Press cylinder rollers (16) against compression springs (15) and insert retaining plates (085) with the rounded edge pointing outwards.
The retaining plates can be acquired as auxiliary tools via part no. 126 277 00 73 (16 plates).

Insert inside ring of free-wheeling unit (13) whilst rotating in a counter-clockwise direction, then remove retaining plates (085).

Fig 12: Identifying Retaining Plates, Free-Wheeling Unit
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Remove cylinder rollers (16) and roller cage (14) with compression springs (15). Check parts for damage.
Remove outside ring of free-wheeling unit (24).

Fig 13: Identifying Cylinder Rollers, Roller Cage
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Check thrust washer (18) and O-ring (20) for damage and wear.

Fig 14: Identifying Thrust Washer, O-Ring
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Measuring
Check axial play of free-wheeling unit and correct. Check clearance between free-wheeling unit and connector (7) using a feeler gage.
NOTE: The O-rings (12, 20) must not be installed during the measurement.

Fig 15: Identifying Axial Play Of Free-Wheeling Unit
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Correct clearance to 0.05 - 0.2 mm using shims (22); then insert O-rings (12 and 20) (figure to items 12, 16).
Place shims (22) in connector (7).
Hold free-wheeling unit together and insert circlip into connector.

Fig 16: Identifying Shims, Connector, Free-Wheeling Unit
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