G26.40-A001-08
1 | Main shaft | 4 | Bolts | 6 | Threaded hole | ||
2 | Bolts | 5 | Oil pipe bracket | 7 | Oil pipe | ||
3 | Countershaft |
G26.40-A002-09
8 | Transmission oil temperature sensor | 10 | Bearing pin | 12 | Rear section of transmission housing | ||
9 | Countershaft rpm sensor | 11 | Bolts |
7 | Oil pipe |
12 | Rear section of transmission housing |
13 | Drift |
14 | Dowel pins |
G26.40-A003-02
G26.40-A004-02
12 | Rear section of transmission housing |
15 | Reverse gear |
A | Collar |
G26.40-A005-11
7 | Oil pipe |
16 | Fuse |
17 | Reverse gear shift fork |
18 | 1st and 2nd gear shift fork |
19 | 3rd gear and 2nd constant speed gear shift fork |
20 | Splitter box transmission shift fork |
22 | Shift rail |
23 | Shift rail |
24 | Shift rail |
G26.10-A004-12
21 | Sliding blocks |
G26.10-A005-01
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. | |
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. | |
Topical note | Notes on self-locking nuts and bolts | ||
Notes on compressed air connection systems | |||
Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | |||
| Assemble | ||
1 | Assemble drive shaft. | ||
2 | Assemble countershaft (3). | ||
3 | Assemble main shaft (1). | ||
4 | Clean sealing surfaces on transmission housing rear section (12) and transmission housing front section. | ||
5 | Insert main shaft (1) and countershaft (3) together with drive shaft into transmission housing. | Secure main shaft (1) and countershaft (3) to each other using a suitable tool. | |
6 | Insert shift rails (22, 23, 24) into transmission housing. | Observe installation position of shift rails (22, 23, 24). | |
7 | Check sliding blocks (21). | If wear or damage is detected: | |
| |||
Replace respective sliding blocks (21). | |||
8 | Check reverse gear shift fork (17), 1st and 2nd gear shift fork (18), 3rd gear and 2nd constant speed gear shift fork (19), as well as splitter box transmission shift fork (20). | If wear or damage is detected: | |
| |||
Replace corresponding component. | |||
9 | Insert sliding blocks (21) into shift forks (17, 18, 19, 20). | Ensure that the sliding blocks (21) are seated correctly. Coat sliding blocks (21) lightly with clean transmission oil. | |
10 | Install reverse gear shift fork (17), 1st and 2nd gear shift fork (18), 3rd gear and 2nd constant speed gear shift fork (19), as well as splitter box transmission shift fork (20). | ||
11 | Insert retainer (16) of shift rail (22) (reverse gear). | ||
12 | Install oil pipe (7). | Observe installation position of oil pipe (7). | |
13 | Apply sealant to sealing surface of transmission housing front section. | Loctite 5203 sealant | |
14 | Insert reverse idler gear (15) into transmission housing rear section (12). | Observe installation position; the collar (A) points downward towards the clutch. | |
15 | Insert drift (13) through hole in transmission housing rear section (12). | ||
| Assembly aid for removal/installation of transmission housing rear section | ||
The drift (13) is used for counterholding/centering the oil pipe (7). | |||
16 | Carefully lower transmission housing rear section (12) little by little onto transmission housing front section while counterholding oil pipe (7) at previously inserted drift (13). | Make sure that the reverse idler gear (15) does not knock against the bearing of the countershaft. | |
17 | Screw in screws (11). | Screws (11) have different lengths, observe installation position. | |
Screw/bolt, transmission housing rear section to transmission housing front section | |||
18 | Align shift forks (17, 18, 19, 20) and screw in new bearing pins (10). | Helper required. | |
Shift fork bearing pin at transmission housing | |||
19 | Install transmission oil temperature sensor (8) and countershaft rpm sensor (9). | Screw, temperature sensor to transmission | |
Bolt, countershaft rpm sensor to transmission housing | |||
20 | Pull drift (13) out of hole in transmission housing rear section (12). | ||
21 | Install reverse idler axle. | ||
Screw, reverse idler axle retaining plate | |||
Extractor | |||
Alignment punch | |||
Threaded insert | |||
22 | Install oil pump. | ||
23 | Remove screw from threaded hole (6) and remove oil pipe bracket (5) from transmission. | ||
24 | Remove clamping plate from countershaft (3) and main shaft (1). | ||
25 | Install shift piston of splitter box. | ||
26 | Install countershaft brake (VGW-B). | ||
27 | Install drive shaft bearing cap. | ||
28 | Attach compressed-air line and electrical wiring harness with brackets to transmission. | ||
29 | Connect electrical connectors at transmission control unit (TCM), transmission oil temperature sensor (8), main shaft rpm sensor and countershaft rpm sensor (9). | ||
30 | Attach transmission to engine. |
714 589 21 63 00
Threaded insert
715 589 03 15 00
Alignment punch
343 589 00 33 01
Extractor
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