Mercedes 2626 AK 6x6

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pairospam
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Re: Mercedes 2626 AK 6x6

#1081 Beitrag von pairospam » 2020-04-29 22:58:51

The next day, I easily removed the pressure plate with the aid of the winch and then carefully removed the flywheel. At inspection, the race was nice and evenly polished, as it should be, but there were clear traces of oil leaking from the retainer that, on its turn, looked pretty healthy too. Hmm…
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Eduardo had to go to Valparaíso himself to pick some spares so he offered himself fully hearted (!?) to get a new retainer for me profiting of the trip.

What to do in the meantime? He had given me an advice on what to do to extract the pin of the intermediary gear some days ago after seing the striking method did not work, but I had not given it a chance… until then.

Adapting things a little to follow his idea, I cut the sliding hammer and left the threaded extreme welded to the bolt to use it as a puller shaft. A couple of pieces of discarded and broken bearings served as spacers and the top of the self-made extractor gave stand and grip for the nut. Easy.
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And it actually was. Uh.

Began to turn the big wrench clockwise and, after a minimum effort compared with the sliding hammer madness, there was a sudden release and the pin popped out from the surface of the gear housing. Great!
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I was thinking on using the heating stuff to take the pin out, but this was far more easy and less destructive. Oh, I really like my brother in law!

Actually, it was only the beginning of the extraction that required a lot of other maneuvers and improvised spacers and patience, though, after a little while, the bloody pin was finally out in my hands and the way was free to access to all the bolts that kept the gear box fixed to the gear housing. Good.
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Carmen was happy too and wasted not time to remind me to follow his brother’s advices, always. I know, I know…

Covered or wrapped all the parts and pieces, swept the floor and made order for good, preparing the place for the disassembling of the gear box that would probably take place in the next working session.

I was happy, and everything went far more easy than expected, beginning for the disassembling of the engine.

Sometimes a seemingly big job is just the fear of the annoyance and hassle you assume it will bring to you, and turns out it is nothing more than a job, another simple job you have to face and accomplish with the best of moods.

Everything happens for a reason.

Greetings from Chile.

tooFATtoDRIVE
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Re: Mercedes 2626 AK 6x6

#1082 Beitrag von tooFATtoDRIVE » 2020-04-30 7:51:30

Pairo, given the uncertainty of the future as we all are experiencing right now, it is great to see one contanst, unchanged and ongoing activity - your excellent, informative, well-documented and very very interesting posts! These really keep the madness from creeping in my mindset. It is great to see constant progress!

a90
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Re: Mercedes 2626 AK 6x6

#1083 Beitrag von a90 » 2020-05-02 10:22:03

Thanks for all your contributions Pairo!

Keep save and healthy.

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Re: Mercedes 2626 AK 6x6

#1084 Beitrag von pairospam » 2020-05-04 16:12:59

Guys:

Life is pretty much uncertain, it has always been. We just tend (or pretend) to forget it.

We have to dream, work, love, laugh, and travel as we and the world will stay forever, for it all could end today.

Keep up with your lives. Glad to help.


Pairoa

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Re: Mercedes 2626 AK 6x6

#1085 Beitrag von pairospam » 2020-05-14 3:17:45

A few more words and pictures, hoping everyone is fine:

Another autumn had arrived, though the poplars had got rid of their leaves a little prematurely because of the dryness. Here the seasons tend to shift abruptly, but this year we had days of extreme heat, then cold days followed by more very hot days, alternating randomly as if there was no big order. Weather is crazy.

At least the air was fresher and you could see some clouds covering part of the morning sky, and the dogs were always as happy as myself to go running.
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I went to pick the new adjusting cone for the gear shifting rod to Verardo’s machineshop and got the shiny piece that, unfortunately, looked better than it screwed into the clamping piece. I would have to take it back for a repass, but that would have to be later in time as I had not precisely much time to go around.
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Eduardo, my brother-in-law, brang the new retainer for the pressure plate profiting of one of his trips to get spares to keep on with his business. The retainer was the same brand but looked more robust.
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After cleaning all the pieces and surfaces for good, I removed the old retainer, that in fact looked like new, and made sure there was no damage to the housing. If something was wrong it had to be the retainer.
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If I inadvertently damaged the retainer, it had to be during the installation of the pressure plate when assembling the engine, some time ago. So, this time I proceeded very carefully and hung the plate from the winch and used two extension bars from the tool sets that fitted perfectly to guide the plate smoothly into place. Easy.
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I had to go back in time to look for the torque settings for the bolts that secured the plate to the cranckshaft, but finally found them in an e-mail from 2011.

Then I put the adapter flywheel back on and adjusted the disc position with a steel strut, by eye only, trusting it would be a just one-time maneuver.
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And it was. The intermediate shaft went in a perfectly centered clutch disc and the bell housing was secured with the many bloody bolts, with the appropriate torque, of course.

I bolted the engine supports to the bell housing, hung the engine from the winch, just enough to allow removing the wooden pieces from under the exhaust manifold, and then installed the clutch cylinder back on.
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And then the oil leak issue of the back of the engine was solved. Now it was a matter of cranking the engine and see how it worked, pretty confidently… with fingers crossed.

The gearbox, oh yes. Well, I got the portable winch near and rescued the chains from a forgotten box in the corner of the shop. The chains were more robust than the ropes and I wanted to use them to hang the gear box while separating it from the gear housing, but it was soon clear that they would damage the pretty sharp metallic edges, no matter what kind of arrangement I made with wood pieces. So, I got some ropes and hung the heavy box with them prior of taking the last bolts that kept both pieces together.
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Naturally, there were among them some Allen bolts for which there were no appropriate Allen sockets, so I had to go out to buy some.

Then, after removing the bolts and with the aid of some precisely aimed strikes, the big parts separated nice and quietly.
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Re: Mercedes 2626 AK 6x6

#1086 Beitrag von pairospam » 2020-05-14 3:25:15

Some of the built-in circuits for the lubrication were clogged by the filthy gelly oddity found everywhere in the gearbox. Better for the future of the gears having disassembled it.
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The gear box was a pretty heavy bastard, though I managed to accommodate it to have it resting on the side without taking it out from the winch. That way the main shaft was exposed upwards, ready to be taken out. Ready?
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Soon after putting the gear box on a stable platform on the same trolley, I heard Carmen shouting it was time to go. Another week had passed and the progresses were quite slow, though at least there were progresses. I was happy.
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Covered it all and made order. I had been not working in the Merkabah on the weekends as my full attention had shifted to the new house, still in the building process, with the classic delays and problems related to the building itself and the contingency due to the bloody viruzzz.

The same contingency almost left my father with no job, as his clients requested a pilot less than 60 years old because of the risk of the covid 19. Fortunately, experience and common sense prevailed and he went to work far north.

I put a really beautiful picture of the helo taken by one of his passengers with a serious camera while passing by, with the massive and gorgeous northern Andes as framing.
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At the shop, next monday, to remove the main shaft and the gears from the box I needed to remove first the big bearing on the back. It was big and stuck like an avalon, as expected. Working carefully with the sledgehammer and a piece of bronze I reached to get it out of the case, milimeter by milimeter, just by using stoneage tech, but there was still a long way to go before removing it from the shaft itself. Hmm…
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Eduardo approached and suggested to use hydraulic power instead of Neanderthalis strenght, again. I sighed and looked around and found the once projected support for the jack to push the kingpins on the steering knuckles. The ugly and odd looking thing actually was never used because the pins were put, frozen, by the sole push of the hand. It seemed a good idea at that time, though.
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I made some measurements, cut the two pillars according to them and fixed the hydraulic jack pretty simply with a couple of pieces of steel firmly tacked to the base.
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Re: Mercedes 2626 AK 6x6

#1087 Beitrag von pairospam » 2020-05-14 3:39:10

Then, drilled a couple of holes on the plates that served as stabilizers to match the bores on the cage to have a cleaner and tougher grip, and hung the jack to finally weld the pillars perpendicular to the holding plates with a pretty thick welding. And that was it: another Pairoa’s port-o-power.
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But, always the big BUT, the jack did not work horizontally, as you probably all knew. Well, I didn’t. So, I had to hang the whole bunch of kilos of metal from the winch and put it vertically, or almost vertically to make the jack work.
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It was then just a matter of applying a little pressure on the shaft, only the six millimeters allowed by the play between the gears, change progressively the thickness of the retainers, and eventually the bearing fell soundly on the jack. Took some time, but it worked. Thanks again, brother.
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I got the neo-extractor free from the gear box and put the later back on the trolley to keep on with the disassembling.

Removing the shaft with all the gears from the box was relatively easy thanks to the winch and the ropes. Christ, how heavy they are!
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Once on the working tray, I made a vain try to take the front bearing out using the extractor. No way, and I knew it. Grabbed the powergrinder and the screwdriver and destroyed the outer bronze cage and took the rollers out with no mercy. I then grinded the inner raceway until it was so thin that a couple of strikes broke it loose. I was pretty afraid of damaging the shaft so it took me quite a while to get to that point.
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Once the bearing was out, the locking nut was exposed, another big task in itself. It was pretty clear, again, that the sliding sleeve was freely moving over the synchronizer’s hub as there were no end pieces nor springs at sight.
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I will save you from the carnage of the removal of the locking nut, just tell that I finally asked Eduardo to help me to take it out as I was not able to do it without suffering. The chisel work is definitely not for me.

The following was a surprise: I removed the synchronizer hub and found that the cone on the side of the 3rd gear was also broken, in many pieces. I had seen before one of the little broken pieces when first opening the lateral cover of the the gear case, but I thought it was a piece of the broken 4th gear synchronizer cone.
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Poor Merkabah. They really hurt her.

Removed the synchro cone, the 3rd gear and the needle bearing, exposing the underlying race that actually looked not too bad. The definitive opinion would come from Eduardo, but the problem was that it was as stuck to the shaft as every other piece of metal to each other in that pretty pretty gearbox, hmm…
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I would have to modify the neo-press-extractor-port-o-power to take out the race and probably the other races still waiting to show up when disassembling the rest of the gear shaft. To do that I needed to go to Verardo’s pile of metal junk and get some steel pieces to play with.

One of the mechanicians approached and took me out of my calculations and mental designing reminding me that the Montero was ready for the final test. After quite a big servicing and the swapping of the transfer case they had it ready to check if the transmission was working properly.

Then, Eduardo and I headed for the hardest climb at hand near San Felipe, and put the Montero under stress. The transmission worked perfectly well, and the old and faithful Japanese performed as the same white spider he used to be before the embarrassing episode on the ditch at the countryside.

Eduardo could not resist to make a video, even if it was not the hardest part of the trail. The 4x4 looks good, though.
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When we went back to the shop it was already time to close.

That’s it, for now.

Greetings to you all. Keep the faith.

Pairoa

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Re: Mercedes 2626 AK 6x6

#1088 Beitrag von a90 » 2020-05-14 23:44:13

pairospam hat geschrieben:
2020-05-14 3:17:45
Then I put the adapter flywheel back on and adjusted the disc position with a steel strut, by eye only, trusting it would be a just one-time maneuver.

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And it was. The intermediate shaft went in a perfectly centered clutch disc and the bell housing was secured with the many bloody bolts, with the appropriate torque, of course.
This is indeed quite tricky, if the disc is not exactly lined up, you'll end up with the gearbox not fitting.

When we had the gearbox of my LP out for clutch replacement we had nothing as a reference and we had the primary drive taken out for line up. Since the gearbox was also disassembled is was easy to do and once the clutch plate was lined up we placed the primary shaft back in the gearbox. Assembly was easy.

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Re: Mercedes 2626 AK 6x6

#1089 Beitrag von pairospam » 2020-05-16 5:38:13

a90:

Hello and yes, I remembered pretty well how tricky it was the first time, ending up in steel porno, but I definitely wanted not to disassemble any more of the bell housing or whatever.
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Life, God, the engine... everything seemed to be cooperating this time. Why should it be so difficult? Just went on, with trust.

Cheers.


Pairoa

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