Assemble transmission

AR26.10-G-0010AD

Assemble transmission

07.05.2018

Transmission

715.366 in model 800

1

Compressed-air line

13

Shift unit

25

Bearing pin

2

Splitter group cylinder

14

Reverse gear

26

Tapered roller bearing outer race

3

Splitter group shift rod

15

Center section of transmission housing

27

Tapered roller bearing outer race

4

Front section of transmission housing

16

Shim

28

Countershaft brake

5

Screw plug

17

Tapered roller bearing outer race

29

Drive shaft bearing cap

6

Springs

18

Range group

30

Reverse idler shaft

7

Catch bolt

19

Main shaft

33

Retaining ring

8

Sliding blocks

20

Synchronizer cone with synchronizer ring and annular spring

B501

Main shaft rpm sensor

9

Oil pipe

21

Sliding sleeve

B502

Countershaft rpm sensor

10

Shift fork for splitter group

22

Drive shaft

B505

Transmission oil temperature sensor

11

Countershaft

23

Electric line

D

Position of reverse idler gear

12

Tapered roller bearing outer race

24

Shift

9

Oil pipe

11

Countershaft

13

Shift unit

15

Center section of transmission housing

19

Main shaft

50

Holding device

40

Holding device

41

Shaft

42

Scale

15

Center section of transmission housing

45

Holding device

Installation diagram for screws securing transmission housing center section (15) to transmission housing front section (4)

A

Screw (screw length 62 mm)

B

Bolt (bolt length 83 mm)

C

Screw (screw length 94 mm)

19

Main shaft

69

Oil restrictor

72

Transmission

73

Assembly device

 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

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-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



Assemble

1

Assemble countershaft (11).

AR26.50-G-4775AD

2

Assemble drive shaft (22).

AR26.50-G-4744AD

3

Assemble main shaft (19).

AR26.50-G-0428AD

4

Attach holding device (45) for shift unit (13) to transmission housing center section (15).

 Holding fixture

*715589063100

5

Attach assembly device (73) to transmission housing center section (15) and move to vertical position.

AR26.10-W-0001-01HE

 Assembly device

*715589083100

6

Grease contact surface of tapered roller bearing outer race (17), push spacer disk (16) onto tapered roller bearing outer race (17) and install in transmission housing center section (15) from inside up to contact using a suitable drift.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

7

Grease contact surface of tapered roller bearing outer race (12) and install in transmission housing center section (15) from inside up to contact using a suitable drift.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

8

Oil needle bearing, install reverse idler gear (14) with needle bearing and bushing in transmission housing center section (15) and push to one side (arrow D).

9

Install main shaft (19), countershaft (11), shift unit (13) and oil pipe (9) with holding device (50) in transmission housing center section (15).

AR26.50-W-4000-02HA

 When installing the shift unit (13), the reverse idler gear (14) must be pushed to one side (arrow D).

 Clamping device

*315589023100

 Retaining device

*715589013100

 Holding fixture

*715589063100

10

Remove holding device (50) from main shaft (19), countershaft (11), shift unit (13) and oil pipe (9).

11

Oil synchronizer cone and fit on main shaft (19) with synchronizer ring and annular spring (20).

12

Install sliding sleeve (21).

 The long collar must point towards the output.

13

Grease tapered roller bearing of drive shaft (22), push countershaft (11) to one side and install drive shaft (22).

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

14

Center reverse idler gear (14) and insert reverse idler shaft (30).

 Bolt, reverse idler shaft retaining plate to transmission housing

*BA26.40-N-1007-01HA

15

Grease radial shaft sealing ring and install in transmission housing front section (4) together with pilot bushing for splitter box shift rod (3).

AR26.35-W-0002-01HA

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

16

Clean sealing surfaces on transmission housing front section (4) and on transmission housing center section (15), and coat with sealant.

Loctite 5203 sealant

*BR00.45-Z-1015-01A

17

Install transmission housing front section (4).



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

AR26.40-W-2470-08HA

 Shift fork bearing pin at transmission housing

*BA26.35-N-1001-01HA

Loctite 5203 sealant

*BR00.45-Z-1015-01A

 Drift

*715589091500

 Alignment punch

*715589031500

 Puller

*715589083300

 Retaining device

*715589053100

 Holding device

*715589073100

18

Tighten screws (A, B, C) around the circumference of the transmission housing center section (15).

 Pay attention to different lengths of bolts.

 Bolt, transmission housing front section to transmission housing center section

*BA26.40-N-1001-01HA

19

Remove centering drift from oil pipe (9) and install retaining ring (33) on oil pipe (9).

20

Grease contact surface of tapered roller bearing outer races (26, 27) and install these up to contact using a suitable drift.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

21

Coat screw plug (5) with sealant and install catch bolt (7) with springs (6) and screw plug (5).

 Splitter group shift rod lock to transmission housing

*BA26.35-N-1003-01HA

Loctite 5203 sealant

*BR00.45-Z-1015-01A

22

Use holding device (40) to fix shift rails of shift unit (13) in neutral position.

 The shaft (41) on the holding device (40) must be at zero degrees on the scale (42).

 Drift

*715589091500

 Holding device

*715589246300

23

Pull out splitter box shift rod (3) using assembly tool.



WF58.50-N-2635-02A

24

Determine shims of drive shaft (22) and countershaft (11).

AR26.50-W-0410-03HA


Use a torque wrench with maximum indicator only.
The tapered roller bearing outer races (26 and 27) will otherwise be damaged.

Drive shaft bearing pretension

*BE26.50-N-1003-01HA

Setting tolerance of bearings on countershaft

*BE26.50-N-1004-01HA

 Preload of bushings on drive shaft and countershaft for determining shims

*BA26.50-N-1003-01HA

 Torque wrench

*000589672100

 Pliers

*715589013700

 Clamping plates

*715589156300

25

Install countershaft brake (28) with determined shim.

AR26.50-G-6000AD

 The oil grooves of brake disks must be aligned.

26

Install drive shaft bearing cap (29) with determined shim.

AR26.30-G-1020AD

27

Detach transmission (72) from assembly device (73) and place transmission (72) horizontally.

28

Detach holding device (45) for shift unit (13) from transmission housing center section (15).

29

Press in splitter box shift rod (3) using assembly tool.



WF58.50-N-2635-02A

30

Install shift piston of splitter box.

AR26.35-G-0001AD

31

Install splitter box cylinder (2).

AR26.18-G-1001AD

32

Install transmission oil temperature sensor (B505).

 Transmission oil temperature sensor to transmission housing

*BA26.19-N-1005-01HA

33

Install countershaft rpm sensor (B502).

 Bolt, countershaft rpm sensor to transmission housing

*BA26.19-N-1007-01HA

34

Install main shaft rpm sensor (B501).

 Bolt, main shaft rpm sensor to transmission housing

*BA26.19-N-1006-01HA

35

Install gearshift system (24).

AR26.60-G-0001AD

36

Install transmission positioner (Y900).

Transmission positioner from the company Festo

AR26.21-G-0006AD

Transmission positioner from the company Wabco

AR26.21-G-0006ADB

37

Install oil restrictor (69) on main shaft (19).

AR26.50-G-0004AD

38

Install range group (18).

AR26.31-G-3100AD

39

Attach compressed-air lines and electrical lines (23) with brackets to transmission (72).

 Screw/bolt, bracket to transmission

*BA26.40-N-1009-01HA

40

Reconnect electrical connectors to 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).

41

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

42

Install pneumatic central clutch release bearing.

Transmission 715.366 in model 800

AR25.20-G-0182N

43

Install transmission (72).

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

Test and adjustment values for gear set

Number

Designation

Transmission 715.356/366

BE26.50-N-1003-01HA

Drive shaft bearing pretension

mm

0,0...-0,15

Test and adjustment values for gear set

Number

Designation

Transmission 715.356/366

BE26.50-N-1004-01HA

Setting tolerance of bearings on countershaft

mm

-0,10...+0,05

 Sensors, transmitters

Number

Designation

Transmission 715.356/366

BA26.19-N-1005-01HA

Transmission oil temperature sensor to transmission housing

Nm

60

 Sensors, transmitters

Number

Designation

Transmission 715.356/366

BA26.19-N-1006-01HA

Bolt, main shaft rpm sensor to transmission housing

Nm

10

 Sensors, transmitters

Number

Designation

Transmission 715.356/366

BA26.19-N-1007-01HA

Bolt, countershaft rpm sensor to transmission housing

Nm

10

 Splitter group

Number

Designation

Transmission 715.356/366

BA26.35-N-1001-01HA

Shift fork bearing pin at transmission housing

Nm

120

 Splitter group

Number

Designation

Transmission 715.356/366

BA26.35-N-1003-01HA

Splitter group shift rod lock to transmission housing

Nm

30

 Housing

Number

Designation

Transmission 715.356/366

BA26.40-N-1001-01HA

Bolt, transmission housing front section to transmission housing center section

Nm

80

 Housing

Number

Designation

Transmission 715.356/366

BA26.40-N-1007-01HA

Bolt, reverse idler shaft retaining plate to transmission housing

Nm

70

 Housing

Number

Designation

Transmission 715.356/366

BA26.40-N-1009-01HA

Screw/bolt, bracket to transmission

M6

Nm

10

M8

Nm

25

M10

Nm

50

 Gear set, shafts

Number

Designation

Transmission 715.356/366

BA26.50-N-1003-01HA

Preload of bushings on drive shaft and countershaft for determining shims

Nm

10

Repair materials

Number

Designation

Order number

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