Disassemble transmission

AR26.10-G-0005AD

Disassemble transmission

28.08.2018

Transmission

715.366 in model 800

1

Compressed-air line

14

Reverse gear

27

Tapered roller bearing outer race

2

Splitter group cylinder

15

Center section of transmission housing

28

Countershaft brake

3

Splitter group shift rod

16

Shim

29

Drive shaft bearing cap

4

Front section of transmission housing

17

Tapered roller bearing outer race

30

Reverse idler shaft

5

Screw plug

18

Range group

31

Threaded insert

6

Springs

19

Main shaft

32

Slide hammer puller

7

Catch bolt

20

Synchronizer cone with synchronizer ring and annular spring

33

Retaining ring

8

Sliding blocks

21

Sliding sleeve

B501

Main shaft rpm sensor

9

Oil pipe

22

Drive shaft

B502

Countershaft rpm sensor

10

Shift fork for splitter group

23

Electric line

B505

Transmission oil temperature sensor

11

Countershaft

24

Shift

A

Position of reverse idler gear

12

Tapered roller bearing outer race

25

Bearing pin

13

Shift unit

26

Tapered roller bearing outer race

9

Oil pipe

11

Countershaft

13

Shift unit

15

Center section of transmission housing

19

Main shaft

50

Holding device

4

Front section of transmission housing

43

Pulling device

44

Adapter

19

Main shaft

69

Oil restrictor

72

Transmission

73

Assembly device

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Notes on compressed air connection systems

AH00.18-N-0001-01A



Disassemble

1

Remove transmission (72).

 Choose procedure according to accessibility and design.
See information from body manufacturer.

2

Disconnect electrical connectors from transmission control unit (TCM) (A5), pneumatic central clutch release bearing, transmission oil temperature sensor (B505), main shaft rpm sensor (B501) and countershaft rpm sensor (B502).

3

Detach compressed-air lines from transmission positioner (Y900), range group cylinder and power take-off.

4

Detach compressed-air lines and electrical lines (23) with brackets from transmission (72).

5

Remove pneumatic central clutch release bearing.

Transmission with Mercedes PowerShift 3

AR25.20-G-0182N

6

Remove range group (18).

AR26.31-G-3100AD

7

Remove oil restrictor (69) from main shaft (19).

Only if fitted.

AR26.50-G-0004AD

8

Remove transmission oil temperature sensor (B505).

9

Remove countershaft rpm sensor (B502).

10

Remove main shaft rpm sensor (B501).

11

Remove transmission positioner (Y900).

Transmission positioner from the company Festo

AR26.21-G-0006AD

Transmission positioner from the company Wabco

AR26.21-G-0006ADB

12

Remove gearshift system (24).

AR26.60-G-0001AD

13

Remove reverse idler shaft (30) using threaded insert (31) and impact extractor (32).



Threaded insert for removing reverse idler shaft

WF58.50-N-2650-06A

 Impact extractor

*355589016300

14

Remove splitter box cylinder (2).

AR26.18-G-1001AD

15

Remove splitter box shift piston.

AR26.35-G-0001AD

16

Attach assembly tool to splitter box shift rod (3).



WF58.50-N-2635-02A

17

Install assembly device (73) at transmission (72) and position vertically.

AR26.10-W-0001-01HE

 Assembly device

*715589083100

18

Unscrew screw plug (5) and remove springs (6) and catch bolt (7).

 The screw plug (5) is spring-loaded.

19

Remove countershaft brake (28).

AR26.50-G-6000AD

20

Remove drive shaft bearing cap (29).

AR26.30-G-1020AD

21

Remove retaining ring (33) on oil pipe (9).

22

Unscrew both bearing pins (25).

 Extraction claw

*715589063300

 Impact extractor

*355589016300

23

Remove screws around circumference of transmission housing center section (15).

24

Attach pull-off device (43), thrust piece 03, hand pump, hydraulic hose, hydraulic cylinder and the two adapters (44) to transmission housing front section (4).

 disassembly kit

*715589196300

 Puller

*715589083300

 Hand pump

*652589003321

 Hydraulic hose (complete)

*652589003323

 Hydraulic cylinder

*715589153400

 Adapter

*715589123400

 Adapter

*715589113400

25

Press transmission housing front section (4) approx. 30 mm off transmission housing center section (15).

 Do not damage sealing surfaces.

26

Unhook splitter box shift rod (3) from splitter box shift fork (10) and pull out of transmission housing front section (4) using assembly tool.



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

27

Detach hand pump, hydraulic hose, hydraulic cylinder and the two adapters (44).

28

Attach holding device to pull-off device (43).

 Retaining device

*715589053100

 Puller

*715589083300

29

Remove transmission housing front section (4).

30

Detach holding device, pull-off device (43) and thrust piece 03 from transmission housing front section (4).

31

Remove radial shaft sealing ring and pilot bushing for splitter box shift rod (3) from transmission housing front section (4).

AR26.35-W-0002-01HA



Adapter for removing guide bush in front section of transmission housing

WF58.50-N-1000-01A

 Counter stay

*000589333300

 Internal extractor

*000589273300

32

Remove tapered roller bearing outer races (26, 27) from transmission housing front section (4).

 Use a suitable drift.

33

Remove splitter box shift fork (10) with sliding blocks (8).

34

Push countershaft (11) to one side and remove drive shaft (22).

35

Remove sliding sleeve (21).

36

Remove synchronizer cone with synchronizer ring and annular spring (20).

37

Attach holding devices (50) to main shaft (19), countershaft (11), shift unit (13) and oil pipe (9).

 Retaining device

*715589013100

 Holding fixture

*715589063100

38

Push reverse idler gear (14) to one side (arrow A), remove main shaft (19), countershaft (11), shift unit (13) and oil pipe (9) from transmission housing center section (15) and clamp in clamping device.

 Clamping device

*315589023100

39

Remove oil pipe (9).

40

Remove countershaft (11) from holding device (50).

41

Remove shift unit (13) from holding device (50) and from main shaft (19).

42

Remove main shaft (19) from holding device (50).

43

Remove reverse idler gear (14) from transmission housing center section (15).

44

Remove tapered roller bearing outer race (12) from transmission housing center section (15) using a suitable drift.

45

Remove tapered roller bearing outer race (17) and spacer disk (16) from transmission housing center section (15) using a suitable drift.

46

Detach assembly device (73) from transmission housing center section (15) and set down horizontally.

47

Disassemble main shaft (19).

AR26.50-G-0427AD

48

Disassemble drive shaft (22).

AR26.50-G-4744AD

49

Disassemble countershaft (11).

AR26.50-G-4775AD