IMPACT 3.

0 Monday, 6 May 2013

Chassis ID Path
43/Repair/FM9, VT2009B/Main shaft, overhaul. Unit removed

Model Identity
FM9 79184077

Publish date Operation No.

Tuesday, 21 February 2006 43173-5

43173-5 Main shaft, overhaul

Unit removed

Special tools: 9990036, 9992454, 9992619, 9992621, 9992653, 9992671, 9994731, 9996222, 9996280, 9996454,
9996498, 9996499, 9996500, 9996600, 9996602, 9996603, 9996635, 9996725, 9996901, 9998651

Removal

Pull off the support bearing.

Special tools: 9992621 9994731 9996222 9996454 9996600 9996602 9996603 9996635 9998651

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IMPACT 3.0 Monday, 6 May 2013

Remove the circlip.

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IMPACT 3.0 Monday, 6 May 2013

Pull off 3rd–4th gears' synchronising ring.

Note: Put your hand on the engaging ring so that the synchronising ring does not fall apart.

Special tools: 9990036 9992619 9992653 9992671 9996222 9996454 9996498 9996499 9996500

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IMPACT 3.0 Monday, 6 May 2013

Remove the 3rd gear and needle bearing.

Pull off the 1st gear and the spacer ring and the bearing race for the 3rd gear. Remove the needle bearing.

Special tools: 9992619 9992671 9996222 9996454 9996498 9996499 9996500

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IMPACT 3.0 Monday, 6 May 2013

Remove the washer and lock ring.

Remove:

engaging ring
inner cone
intermediate cone
outer cone
pusher plate.

8
Turn the shaft over so that the sun gear is facing upwards.

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IMPACT 3.0 Monday, 6 May 2013

Pull off:

gear for the reverse gear

roller bearing
spacer ring
sun gear

Remove engaging sleeve.

Special tools: 9992619 9992671 9992653 9996222 9996454 9996498 9996499 9996500

10

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IMPACT 3.0 Monday, 6 May 2013

Pull off:

gear for crawler gear

hub
bearing race for the reverse wheel's needle bearing.

Special tools: 9992619 9992671 9992653 9996222 9996454 9996498 9996499 9996500

11

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IMPACT 3.0 Monday, 6 May 2013

Push off the 2nd gear and the 1st–2nd gears' synchronising ring.

Note: Put your hand on the engaging ring so that the synchronising ring does not fall apart.

12
Take apart the 1st–2nd and 3rd–4th gears' synchronising rings. Put a cloth around the engaging sleeve so that the
detent pins (4 large and 2 small) and the springs do not fall apart unchecked when being taken apart.

Note: Do not mix up the detent components for the various synchronisations.

Cleaning

13
Clean and check all components.

Note: The intermediate cones must not be washed.

14
Check the wear surfaces of engaging rings and synchronising rings. Rings with partly or fully worn grooves or with
blued surfaces must be replaced. Check the coupling teeth.

15
Lubricate in all needle bearings, roller bearings, synchronising cones and gears with gearbox oil when assembling. The
detent bodies' springs must be replaced with new ones and oiled in after installation.

Fitting

16

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IMPACT 3.0 Monday, 6 May 2013

Put the engaging sleeve for the 1st–2nd gears' synchronising ring on a work bench. The cutout on the engaging sleeve
should be facing upwards.

17

Put on the guide sleeve with the longer neck turned upwards in the engaging sleeve.

Note: Two bars in each of the large cutouts on the guide sleeve. The guide sleeve's small cutout should come to the
left of the engaging sleeve's cutout.

18

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9 / 38
IMPACT 3.0 Monday, 6 May 2013

Push the two springs and the two smaller detent pins into the guide sleeve. Push the guide sleeve down into the
engaging sleeve.

19

Place mandrel 9996280 as a base for the guide sleeve, which facilitates the installation of the springs and detent pins.
Push down the engaging sleeve towards the bench and put in the four springs and the four larger detent pins from
above. Push in the detent pins. If necessary, use an appropriate mandrel from above and a finger from below.

Special tools: 9996280

20

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10 / 38
IMPACT 3.0 Monday, 6 May 2013

Put in the disc spring with the lowest point towards the neck of the guide sleeve.
If you push on the disc spring's outer edge it should lift from the opposite side.

21

Put the pusher plate on the guide sleeve with one of the small lugs on the pusher plate against the cutout on the
engaging sleeve.

22

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11 / 38
IMPACT 3.0 Monday, 6 May 2013

Put on the outer cone with the lugs in the same position as the lugs on the pusher plate's arms.

23

Put in the intermediate cone.

24

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IMPACT 3.0 Monday, 6 May 2013

Put in the inner cone. Put the small cutouts in the inner cone on the small lugs on the pressure plate.

25

Put on the engaging ring with the flat side up. The intermediate cone's lugs fit in the holes.

26

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13 / 38
IMPACT 3.0 Monday, 6 May 2013

Pull the engaging sleeve up to neutral position. Be careful, so that the assembled and synchronised components do
not fall apart.

27

Put in the disc spring with the lowest point towards the neck of the guide sleeve.
If you put on the disc spring's outer edge it should lift from the opposite side.

28

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14 / 38
IMPACT 3.0 Monday, 6 May 2013

Put on the pusher plate with the arms in the free cutouts.

29

Put on the outer cone with the lugs in the same position as the pusher plate's arms.

30

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IMPACT 3.0 Monday, 6 May 2013

Put in the intermediate cone.

31

Put in the inner cone. Put the small cutouts in the inner cone on the small lugs on the pressure plate.

32

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IMPACT 3.0 Monday, 6 May 2013

Put on the engaging ring with the flat side up. The intermediate cone's lugs fit in the holes.

33

Put the engaging sleeve for the 3rd–4th gears' synchronising ring on the work bench. The cutout for the engaging
sleeve should be facing upwards.

34

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17 / 38
IMPACT 3.0 Monday, 6 May 2013

Put on the guide sleeve with the narrow neck turned upwards in the engaging sleeve.

Note: Two bars in each of the large cutouts on the guide sleeve. The guide sleeve's small cutout should come to the
left of the engaging sleeve's cutout.

35

Push the two the springs and the two smaller detent pins into the guide sleeve. Push the guide sleeve down into the
engaging sleeve.

36

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18 / 38
IMPACT 3.0 Monday, 6 May 2013

Place mandrel 9996280 as a base for the guide sleeve, which facilitates the installation of springs and detent pins.
Push the engaging sleeve down towards the bench and put on the four springs and the four larger detent pins from
above. Push in the detent pins. If necessary, use an appropriate mandrel from above and a finger from below.

Special tools: 9996280

37

Put in the disc spring with the lowest point against the neck of the guide sleeve.
If you push on the disc spring's outer edge it should lift from the opposite side.

Note: The disc spring's diameter: 95 mm

38

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IMPACT 3.0 Monday, 6 May 2013

Put the pusher plate on the guide sleeve with one of the small lugs on the pusher plate against the cutout on the
engaging sleeve.

39

Put on the outer cone with the lugs in the same position as the pusher plate's arms.

40

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20 / 38
IMPACT 3.0 Monday, 6 May 2013

Put on the intermediate cone.

41

Put in the inner cone. Put the small cutouts in the inner cone on the small lugs on the pressure plate.

42

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21 / 38
IMPACT 3.0 Monday, 6 May 2013

Put on the engaging ring with the flat side up. The intermediate cone's lugs fit into the holes.

43

Pull the engaging sleeve up to neutral position. Be careful, so that the assembled and synchronised components do
not fall apart.

44

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22 / 38
IMPACT 3.0 Monday, 6 May 2013

Put in the disc spring with the lowest point against the neck of the guide sleeve.
If you push on the disc spring's outer edge it should lift from the opposite side.

45

Put on the pusher plate with the arms in the free cutouts.

46

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23 / 38
IMPACT 3.0 Monday, 6 May 2013

Put on the outer cone with the lugs in the same position as the pusher plate's arms.

47

Put in the intermediate cone.

48

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24 / 38
IMPACT 3.0 Monday, 6 May 2013

Put in the inner cone. Put the small cutouts in the inner cone on the small lugs on the pressure plate.

49

Put on the engaging ring with the flat side up. The intermediate cone's lugs fit in the holes.

50
Put the shaft in the press with the splines for the sun gear facing upwards.

51
Put on the needle bearing and the gear for the crawler gear.

52

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IMPACT 3.0 Monday, 6 May 2013

Push on the hub. Use socket mandrel 9996725.

Special tools: 9996725

53

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IMPACT 3.0 Monday, 6 May 2013

Put on the engaging sleeve with the bevelled side downwards.

54

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IMPACT 3.0 Monday, 6 May 2013

Push on the bearing race for the reverse wheel. Use socket mandrel 9996901. Put on needle bearing and the reverse
wheel.

Special tools: 9996901

55

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28 / 38
IMPACT 3.0 Monday, 6 May 2013

Push on the rear bearing. Use socket mandrel 9996901.

Special tools: 9996901

56

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29 / 38
IMPACT 3.0 Monday, 6 May 2013

Push on the spacer ring and the sun gear. Use socket mandrel 9996901.

Special tools: 9996901

57

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IMPACT 3.0 Monday, 6 May 2013

Turn the shaft over. Put on needle bearing and 2nd gear.

58

Put on 1st–2nd gears' synchronising ring.

Note: Take care so that the synchronising assembly does not fall apart. Hold the synchronising ring still and turn the
2nd gear so that the engaging ring falls down in the splines on the gear. Make sure that the outer cone, pusher plate
and recesses in the engaging sleeve are lined up with one another.

59

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IMPACT 3.0 Monday, 6 May 2013

Push the guide sleeve to the bottom. Use socket mandrel 9996725.

Special tools: 9996725

60

Put on lock ring.

61

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IMPACT 3.0 Monday, 6 May 2013

Put on needle bearing and 1st gear.

62

Put on the spacer washer for the 1st gear. Use socket mandrel 9996725.

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IMPACT 3.0 Monday, 6 May 2013

Special tools: 9996725

63

Put on the bearing race for the 3rd gear. Use socket mandrel 9996901.

Special tools: 9996901

64

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34 / 38
IMPACT 3.0 Monday, 6 May 2013

Put on the 3rd gear's needle bearing and gear.

65

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35 / 38
IMPACT 3.0 Monday, 6 May 2013

Put on the 3rd–4th gears' synchronising ring.

Note: Take care so that the synchronising assembly does not fall apart. Check that the outer cone, pusher plate and
the engaging sleeve's cutout line up with one another.

Push on the synchronising assembly. Use socket mandrel 9996901.

Special tools: 9996901

66

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36 / 38
IMPACT 3.0 Monday, 6 May 2013

Fit the retaining ring.

67

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37 / 38
IMPACT 3.0 Monday, 6 May 2013

Push on the support bearing. Use socket mandrel 9992454.

Special tools: 9992454

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