Assemble transmission

AR26.10-G-0010H

Assemble transmission

22.02.2018

Transmission

715.536 in model 800.2/3

Except turbo retarder clutch

1

Compressed-air line

13

Shift unit

25

Shift

2

Splitter group cylinder

14

Center section of transmission housing

26

Bearing pin

3

Splitter group shift rod

15

Reverse gear

27

Tapered roller bearing outer race

4

Front section of transmission housing

16

Reverse gear cap

28

Tapered roller bearing outer race

5

Screw plug

17

Range group

29

Countershaft brake

6

Springs

18

Shim

30

Drive shaft bearing cap

7

Catch bolt

19

Tapered roller bearing outer race

31

Retaining ring

8

Sliding blocks

20

Main shaft

32

Reverse idler shaft

9

Oil pipe

21

Synchronizer cone with synchronizer ring and annular spring

34

Bearing pin

10

Shift fork for splitter group

22

Sliding sleeve

B501

Main shaft rpm sensor

11

Countershaft

23

Drive shaft

B502

Countershaft rpm sensor

12

Tapered roller bearing outer race

24

Electric line

B505

Transmission oil temperature sensor

9

Oil pipe

11

Countershaft

13

Shift unit

14

Center section of transmission housing

20

Main shaft

50

Holding device

14

Center section of transmission housing

33

3rd/4th gear shift fork

34

Bearing pin

40

Holding device

41

Shaft

42

Scale

20

Main shaft

69

Oil pressure control valve

72

Transmission

73

Assembly device

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

 Warning

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension

Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.

AS00.00-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 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

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on compressed air connection systems

AH00.18-N-0001-01A



Assemble

1

Assemble countershaft (11)

AR26.50-G-4775H

2

Assemble drive shaft (23)

AR26.50-G-4744H

3

Assemble main shaft (20)

AR26.50-G-0426H

4

Coat contact surface of tapered roller bearing outer race (19) with lubricant

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

5

Slide spacer washer (18) onto tapered roller bearing outer race (19) and install using suitable drift from the inside up to the contact surface in the center section of transmission housing (14)

6

Coat contact surface of tapered roller bearing outer race (12) with lubricant

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

7

Drive tapered roller bearing outer race (12) into transmission housing center section (14) from the inside as far as the contact surface using a suitable drift

8

Install main shaft (20), countershaft (11) and shift unit (13) using holding device (50) into center section of transmission housing (14)

AR26.50-G-4000-02H

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

 Clamping device

*315589023100

 Retaining device

*715589013100

9

Oil synchronizer cone with synchronizer ring and annular spring (21)

10

Fit synchronizer cone with synchronizer ring and annular spring (21) on main shaft (20)

11

Install sliding sleeve (22).

 The long collar must point towards the output.

12

Push countershaft (11) to one side and coat tapered roller bearing (pilot bearing) on drive shaft (23) with lubricant

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

13

Install drive shaft (23)

14

Coat the thread on both bearing pins (34) with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

15

Lift guide rails of shift unit (13) slightly and screw in bearing pins (34) so that they are flush with the guide rail

16

Install 3rd/4th gear shift forks (33) with sliding blocks and shift rails in sliding sleeve

17

Screw both bearing pins (34) in completely and tighten

 Shift fork bearing pin at transmission housing

*BA26.35-N-1001-01HA

18

Check bearing and bushing of reverse idler gear (15) for wear

If a problem arises



Replace bearing or bushing.

19

Install reverse idler gear (15) with bearing and bushing

 The long collar of the reverse idler gear (15) must point towards the output.

20

Center the reverse gear (15) and install reverse idler shaft (32)

 Bolt, reverse idler shaft retaining plate to transmission housing

*BA26.40-N-1007-01HA

21

Coat radial shaft sealing ring with synthetic grease and install with pilot bushing for splitter box shift rod (3) in transmission housing front section (4)

AR26.35-G-0002-01H

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

22

Clean sealing surfaces on transmission housing front section (4) and transmission housing center section (14) and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

23

Install front section of transmission housing (4)

AR26.40-G-2470-08H



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

Loctite 5203 sealant

*BR00.45-Z-1015-01A

 Shift fork bearing pin at transmission housing

*BA26.35-N-1001-01HA

 Alignment punch

*715589031500

 Retaining device

*715589053100

 Holding device

*715589073100

 Puller

*715589083300

 Drift

*715589091500

24

Tighten screws/bolts around the circumference of the transmission housing center section (14)

 Pay attention to different lengths of bolts.

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

*BA26.40-N-1001-01HA

25

Remove centering drift from the oil pipe (9)

26

Install retaining ring (31) on the oil pipe (9)

27

Detach support of oil pipe (9)

28

Coat tread of tapered roller bearing outer races (27, 28) with lubricant

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

29

Using a suitable drift, install tapered roller bearing outer races (27, 28) up to contact surface

30

Install catch bolt (7) and springs (6)

31

Coat screw plug (5) with sealant and install

Loctite 5203 sealant

*BR00.45-Z-1015-01A

32

Pull out splitter group shift rod (3) using assembly tool



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

33

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

 The marking of the shaft (41) must be at zero degrees on the scale (42).

 Holding device

*715589246300

34

Determine shims of drive shaft (23) and countershaft (11)

AR26.50-G-0410-03H


Only use a  torque wrench with slave pointer.
Otherwise the tapered roller bearing outer races (27, 28) could be damaged.

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

*BA26.50-N-1003-01HA

Drive shaft bearing pretension

*BE26.50-N-1003-01HA

Setting tolerance of bearings on countershaft

*BE26.50-N-1004-01HA

 Torque wrench

*000589672100

 Pliers

*715589013700

 Clamping plates

*715589156300

35

Install countershaft brake (29) with the determined shim

AR26.50-G-6000H

 The oil grooves of brake disks must be aligned.

36

Install bearing cap for drive shaft (30) together with determined shim

AR26.30-G-1020H

37

Clean sealing surfaces on the transmission housing center section (14) and on the reverse gear cap (16)

38

Coat transmission housing center section (14) and reverse idler gear cap (16) with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

39

Install reverse idler gear cap (16)

 Bolt, reverse idler gear cap to transmission housing center section

*BA26.40-N-1008-01HA

40

Remove assembly device (73) from transmission (72) and place transmission (72) into horizontal plane

AR26.10-W-0001-01HE

41

Press in splitter group shift rod (3) using assembly tool



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

42

Install shift piston of splitter group

AR26.35-G-0001H

43

Install splitter group cylinder (2)

AR26.18-G-1001H

44

Install transmission oil temperature sensor (B505)

AR26.19-G-0017H

45

Install countershaft rpm sensor (B502)

AR26.19-G-0018H

46

Install main shaft rpm sensor (B501)

AR26.19-G-0501H

47

Install shift mechanism (25)

AR26.60-G-0001H

48

Install oil pressure control valve (69) on main shaft (20)

AR26.50-G-0004H

49

Install range group (17)

AR26.31-G-3100H

50

Install pneumatic central clutch release bearing

AR25.20-G-0182H

51

Attach air lines and electrical lines with brackets to transmission (72)

 Screw/bolt, bracket to transmission

*BA26.40-N-1009-01HA

52

Connect electrical connectors at transmission control unit (TCM), transmission oil temperature sensor (B505), main shaft rpm sensor (B501) and countershaft rpm sensor (B502)

53

Attach compressed-air lines to transmission positioner and range group cylinder

54

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 715.536

BE26.50-N-1003-01HA

Drive shaft bearing pretension

mm

0,0...-0,15

Test and adjustment values for gear set

Number

Designation

Transmission 715.536

BE26.50-N-1004-01HA

Setting tolerance of bearings on countershaft

mm

-0,10...+0,05

 Splitter group

Number

Designation

Transmission 715.536

BA26.35-N-1001-01HA

Shift fork bearing pin at transmission housing

Nm

120

 Housing

Number

Designation

Transmission 715.536

BA26.40-N-1001-01HA

Bolt, transmission housing front section to transmission housing center section

Nm

80

 Housing

Number

Designation

Transmission 715.536

BA26.40-N-1007-01HA

Bolt, reverse idler shaft retaining plate to transmission housing

Nm

70

 Housing

Number

Designation

Transmission 715.536

BA26.40-N-1008-01HA

Bolt, reverse idler gear cap to transmission housing center section

Nm

50

 Housing

Number

Designation

Transmission 715.536

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 715.536

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