Assemble transmission

AR26.10-G-0010AC

Assemble transmission

22.01.2018

Transmission

715.067 in model 800

1

Annular spring

13

5th and 6th gear gearshift arm

25

Rear section of transmission housing

2

Cover (countershaft)

14

Shift rails

26

Reverse gear shaft

3

Retaining ring

15

Main shaft

27

Lock bolt

4

Retaining ring

16

Cap

28

Front section of transmission housing

5

Grooved ball bearing

17

End cover (only without power take-off)

29

Reverse gear

6

Bearing pin

18

Spacer ring (only without power take-off)

30

Radial shaft sealing ring

7

Bearing pin

19

Pulse wheel

31

Guide tube (only with manual gearshift system)

8

Countershaft

20

Radial shaft sealing ring

B18

Travel and speed rpm sensor (only without transfer case)

9

Drive shaft

21

Output flange

B500

Output shaft rpm sensor (only with transfer case)

10

Retaining ring

22

Pressure plate

B501

Main shaft rpm sensor

11

Cylindrical roller bearing

23

Screw

B502

Countershaft rpm sensor (only with Mercedes PowerShift 3)

12

Shim

24

Supporting arm

B505

Transmission oil temperature sensor

8

Countershaft

15

Main shaft

36

Retaining spring

37

5th and 6th gear synchronizer unit

8

Countershaft

14

Shift rails

15

Main shaft

40

Support plate

41

Bracket

8

Countershaft

21

Output flange

25

Rear section of transmission housing

40

Support plate

42

Screw

43

Mounting irons

A

Output end

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW



Assemble

1

Assemble countershaft (8)

AR26.50-G-4775AC

2

Assemble main shaft (15)

AR26.50-G-0428AC

3

Assemble drive shaft (9)

AR26.50-G-4744AC

4

Install drive shaft (9) in front section of transmission housing (28)

5

Install retaining ring (10) with zero clearance

AR26.50-W-4743-01NA

 Assembly tool

*715589006300

6

Check play between deep-groove ball bearing (5) of drive shaft (9) and retaining ring (10) in front section of transmission housing (28)

AR26.50-W-4743-03NA

Play of grooved ball bearing in front section of transmission housing

*BE26.50-N-1002-01NA

7

Assemble rear section of transmission housing (25)

AR26.40-G-2476AC

8

Insert main shaft (15) and countershaft (8) into the support plate (40)

 Insert suitable spacer with a height of 18 mm (e.g. a nut) into mount of main shaft (15) on mounting plate (40) so that the gears of the main shaft (15) and countershaft (8) mesh.

 Support plate

*715589316300

9

Fix gear for reverse gear into place in neutral using suitable tool

10

Mount shift rails (14) onto main shaft (15)

 Fix shift rails (14) in place using cable ties and holder (41).

 Bracket

*715589106300

11

Remove tool for fixing neutral position of gearwheel for reverse gear in place

12

Insert reverse idler gear (29) into rear section of transmission housing (25)

 The long collar of the reverse idler gear (29) must point towards the drive.

13

Attach rear section of transmission housing (25)

AR26.40-W-2475-08NA

 Secure reverse idler gear (29) when moving the rear section of the transmission housing (25).

 Hydraulic hose (complete)

*652589003323

 Hydraulic cylinder

*715589153400

 Pulling device

*715589123300

 Adapter

*715589113400

 Hand pump

*652589003321

 Adapter

*715589123400

 Sleeve

*715589021400

14

Grease and install reverse idler gear axle (26)

 The reverse idler gear (29) and needle roller bearing must be fixed accurately into place.
Insert  of the reverse idler gear axle (26) by hand, with the thread facing outwards, then drive in with a plastic mallet up to the end stop.

Long-life grease

*BR00.45-Z-1001-06A

15

Clean sealing surfaces on cap (16) and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

16

Install cap (16)

 Cap and housing to transmission housing rear section

*BA26.40-N-1006-01G

17

Grease sealing lip of radial shaft sealing ring (20)

Synthetic grease 50 g

*BR00.45-Z-1027-06A

18

Install pulse wheel (19) and radial shaft sealing ring (20)

 Drift

*715589061500

19

Move rear section of transmission housing (25) into horizontal position and remove mounting plate (40)

20

Install output flange (21), pressure plate (22) and bolt (23)

 Bolt, output flange

*BA26.50-N-1001-01NA

 Retainer wrench

*717589003100

21

Fit mounting plate (40) onto output flange (21) and place rear section of transmission housing (25) onto fitted mounting plate (40)

 Support plate

*715589316300

 Adapter set

*715589226300

22

Remove cable ties from shift rails (14)

23

Screw in locking screws (27) by approx. 4 turns

24

Check play of main shaft (15)

AR26.50-W-0420-10NA

Main shaft end float

*BE26.50-N-1005-01NA

25

Place shim (12) of determined thickness onto main shaft (15)

26

Grease and install tapered roller bearing (11)

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

27

Remove retaining springs (36) from synchronizer unit for 5th and 6th gear (37)

28

Install gearshift swing arm for 5thand 6thgear (13) with sliding blocks

 Observe direction of installation for sliding blocks. The rounded sides of the sliding blocks must face towards the shift fork mounting.

29

Clean sealing surfaces on front section of transmission housing (28) and coat with sealant

30

Attach front section of transmission housing (28) to rear section of transmission housing (25)

 Screw two centering bolts into front section of transmission housing (28) for easier assembly.
The shift rails for the shift unit (14) must glide into the front section of the transmission housing (28). While doing so, turn drive shaft (9) slightly using pliers.

 Transmission housing front section to transmission housing rear section

*BA26.40-N-1003-01G

Loctite 5203 sealant

*BR00.45-Z-1015-01A

 Pliers

*715589003700

31

Install the bearing pins (6, 7) of the gearshift swing arm for 5thand 6thgear (13)

 Align gearshift swing arm for 5thand 6thgear (13) through the opening in the front section of the transmission housing (28) with the bearing pins (6, 7).
To do so, insert bearing pins (6) with thread locking compound.

 Shift fork bearing pin at transmission housing

*BA26.60-N-1004-01NA

Thread locking agent, Loctite 243 (10 ml)

*BR00.45-Z-1133-02A

32

Prop up countershaft (8) on output side (arrow A) to mounting plate (40)

 For support, use a piece of metal of 95 mm length (e.g. a bolt (42) with a minimum Ø of 14 mm).

33

Install deep-groove ball bearing (5)

 Drive inner race of grooved ball bearing (5) up to end stop of countershaft (8).

 Drift

*387589051500

34

Insert retaining ring (4) with zero clearance and adjust with drift

 If necessary, install a retaining ring (4) of a different thickness.

Play of grooved ball bearing on countershaft

*BE26.50-N-1006-01NA

 Drift

*387589051500

35

Detach support between countershaft (8) and support plate (40)

36

Drive in outer race of grooved ball bearing (5) up to end stop in front section of transmission housing (28)

 Drift

*387589051500

37

Insert retaining ring (3) with zero clearance and adjust with appropriate drift

 If necessary install locking ring (3) of a different thickness.

Play of grooved ball bearing in front section of transmission housing

*BE26.50-N-1002-01NA

38

Install new cover (2)

 Drift punch

*314589031500

39

Install annular spring (1)

40

Grease new radial shaft sealing ring (30) on sealing lip and install

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*715589001500

41

Install guide tube (31)

Only for manual gearshift system.

 Guide tube to transmission housing front section

*BA26.40-N-1005-01G

42.1

Install pneumatic central clutch release bearing

With Mercedes PowerShift 3.

42.2

Install release lever

With manual shift mechanism.

43

Place transmission using suitable lifting gear into horizontal plane and remove mounting plate (40)

44

Tighten lock bolts (27)

 Lock bolts in transmission housing

*BA26.60-N-1005-01NA

45

Install shift mechanism

Manual gearshift system

AR26.60-G-0001AC

Mercedes PowerShift 3

AR26.60-G-0001ACA

46

Install transmission positioner (Y900)

Only with Mercedes PowerShift 3rd.

AR26.21-G-0006AC

47

Install spacer ring (18)

Only without power take-off.

48

Clean sealing surface for end cover (17) or power take-off and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

49.1

Mount end cover (17)

Without power take-off.

 End cover to transmission housing rear section

*BA26.40-N-1004-01G

49.2

Install power take-off

With power take-off.

50

Install main shaft rpm sensor (B501)

 Main shaft rpm sensor to transmission housing

*BA26.19-N-1003-01NA

51.1

Install travel and speed rpm sensor (B18)

Without transfer case.

 Travel and speed rpm sensor to transmission

*BA26.19-N-1001-01NA

51.2

Install output shaft rpm sensor (B500)

With transfer case.

 Output shaft rpm sensor to transmission housing

*BA26.19-N-1009-01NA

52

Install transmission oil temperature sensor (B505)

 Transmission oil temperature sensor to transmission housing

*BA26.19-N-1004-01NA

53

Install countershaft rpm sensor (B502) with new O-ring

Only with Mercedes PowerShift 3rd.

 Countershaft rpm sensor to transmission housing

*BA26.19-N-1002-01NA

54

Install lines to electrical connections and brackets

55

Install support arm (24) on left of transmission

Only if fitted.

 Supporting arm to transmission

*BA26.10-N-1002-01NA

56

Install transmission

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

Test and adjustment values for gear set

Number

Designation

Transmission 715.067

BE26.50-N-1002-01NA

Play of grooved ball bearing in front section of transmission housing

mm

0,00...0,07

Test and adjustment values for gear set

Number

Designation

Transmission 715.067

BE26.50-N-1005-01NA

Main shaft end float

mm

1,15 (0,1)

Test and adjustment values for gear set

Number

Designation

Transmission 715.067

BE26.50-N-1006-01NA

Play of grooved ball bearing on countershaft

mm

0,00...0,07

 Manual transmission, complete

Number

Designation

Transmission 715.067

BA26.10-N-1002-01NA

Supporting arm to transmission

Nm

190

 Sensors, transmitters

Number

Designation

Transmission 715.067

BA26.19-N-1001-01NA

Travel and speed rpm sensor to transmission

Nm

40

 Sensors, transmitters

Number

Designation

Transmission 715.067

BA26.19-N-1002-01NA

Countershaft rpm sensor to transmission housing

Nm

40

 Sensors, transmitters

Number

Designation

Transmission 715.067

BA26.19-N-1003-01NA

Main shaft rpm sensor to transmission housing

Nm

40

 Sensors, transmitters

Number

Designation

Transmission 715.067

BA26.19-N-1004-01NA

Transmission oil temperature sensor to transmission housing

Nm

40

 Sensors, transmitters

Number

Designation

Transmission 715.067

BA26.19-N-1009-01NA

Output shaft rpm sensor to transmission housing

Nm

40

 Housing

Number

Designation

Transmission 715.067

BA26.40-N-1003-01G

Transmission housing front section to transmission housing rear section

Nm

60

 Housing

Number

Designation

Transmission 715.067

BA26.40-N-1004-01G

End cover to transmission housing rear section

Nm

60

 Housing

Number

Designation

Transmission 715.067

BA26.40-N-1005-01G

Guide tube to transmission housing front section

Nm

25

 Housing

Number

Designation

Transmission 715.067

BA26.40-N-1006-01G

Cap and housing to transmission housing rear section

Nm

60

 Gear set, shafts

Number

Designation

Transmission 715.067

BA26.50-N-1001-01NA

Bolt, output flange

M12x1.5

Nm

-

M16x1.5

Nm

275

 Shift

Number

Designation

Transmission 715.067

BA26.60-N-1004-01NA

Shift fork bearing pin at transmission housing

Nm

120

 Shift

Number

Designation

Transmission 715.067

BA26.60-N-1005-01NA

Lock bolts in transmission housing

Nm

30

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1008-06A

Grease, silicone-based, 100 g

A 001 989 28 51

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1027-06A

Synthetic grease 50 g

A 001 989 32 51 10

BR00.45-Z-1133-02A

Thread locking agent, Loctite 243 (10 ml)

A 613 989 09 71 09