Assemble transmission

AR26.10-G-0010OH

Assemble transmission

09.11.2017

Transmission

715.536 in model 800.1

1

Compressed-air line

19

Tapered roller bearing outer race

2

Splitter group cylinder

20

Main shaft

3

Splitter group shift rod

21

Synchronizer cone with synchronizer ring and annular spring

4

Front section of transmission housing

22

Sliding sleeve

5

Screw plug

23

Drive shaft

6

Springs

24

Electrical wiring harness

7

Catch bolt

25

Shift

8

Sliding blocks

26

Bearing pin

9

Oil pipe

27

Tapered roller bearing outer race

10

Shift fork for splitter group

28

Tapered roller bearing outer race

11

Countershaft

29

Countershaft brake

12

Tapered roller bearing outer race

30

Drive shaft bearing cap

13

Shift unit

31

Retaining ring

14

Center section of transmission housing

32

Reverse idler shaft

15

Reverse gear

34

Bearing pin

16

Reverse gear cap

35

Main shaft rpm sensor

17

Range group

36

Countershaft rpm sensor

18

Shim

37

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

34

Bearing pin

40

Holding device

41

Shaft

42

Scale

20

Main shaft

69

Oil pressure control valve

72

Transmission

73

Assembly device

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-4775OH

2

Assemble drive shaft (23)

AR26.50-G-4744OH

3

Assemble main shaft (20)

AR26.50-G-0428OH

4

Coat the tread of the 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

Apply coating of lubricant to contact surface of tapered roller bearing outer race (12)

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

7

Drive tapered roller bearing outer race (12) into center section of transmission housing (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-4000-05OH

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

 Clamping device

*315589023100

 Retaining device

*715589013100

9

Position oiled synchronizer cone with synchronizer ring and annular spring (21) onto main shaft (20)

10

Install sliding sleeve (22)

 The long collar must point towards the output.

11

Push countershaft (11) to one side, apply coating of lubricant to tapered roller bearing (pilot bearing) on drive shaft (23) and install drive shaft (23)

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

12

Slightly lift up guide rails of shift unit (13), apply coating of sealant to thread of both bearing pins (34) and screw-in flush with guide rail

Loctite 5203 sealant

*BR00.45-Z-1015-01A

13

Remove shift fork for 3rd/4th gear using sliding blocks and install shift rail into sliding sleeve

14

Screw in both bearing pins (34) completely

 Shift fork bearing pin at transmission housing

*BA26.35-N-1001-01HA

15

Check bearing and bush of reverse idler gear (15) for wear and install reverse idler gear (15) with bearing and bush

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

If there are problems



Replace defective component.

16

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

17

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

AR26.35-G-0002-01OH

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

18

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

Loctite 5203 sealant

*BR00.45-Z-1015-01A

19

Install front section of transmission housing (4)



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

AR26.40-G-2473-02OH

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

20

Screw in bolts around circumference of center section of transmission housing (14)

 Pay attention to different lengths of bolts.

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

*BA26.40-N-1001-01HA

21

Remove centering drift from oil pipe (9) and install retaining ring (31) onto oil pipe (9)

22

Detach support of the oil pipe (9)

23

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

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

24

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

25

Install catch bolt (7) with springs (6)

26

Coat screw plug (5) with sealant and install

Loctite 5203 sealant

*BR00.45-Z-1015-01A

27

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



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

28

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

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

 Holding device

*715589246300

29

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

AR26.50-G-0410-03OH

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

 Clamping plate

*715589296300

30

Install countershaft brake (29) with the determined shim

AR26.50-G-6000OH

 The oil grooves of brake disks must be aligned.

31

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

AR26.30-G-1020OH

32

Clean sealing surfaces on center section of transmission housing (14) and reverse idler gear cap (16) and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

33

Install reverse idler gear cap (16)

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

*BA26.40-N-1008-01HA

34

Remove assembly device (73) from transmission (72) and place transmission (72) in horizontal position

AR26.10-W-0001-01HE

 Assembly device

*715589083100

35

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



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

36

Install shift piston of splitter group

AR26.35-G-0001OH

37

Install splitter group cylinder (2)

AR26.18-G-1001OH

38

Install transmission oil temperature sensor (37)

AR26.19-G-0017OH

39

Install countershaft rpm sensor (36)

AR26.19-G-0018OH

40

Install main shaft rpm sensor (35)

AR26.19-G-0501OH

41

Install shift mechanism (25)

AR26.60-G-0001OH

42

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

AR26.50-G-0008OH

43

Install range group (17)

AR26.31-G-3100OH

44

Install pneumatic central clutch release bearing

AR25.20-G-0182N

45

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

 Screw/bolt, bracket to transmission

*BA26.40-N-1009-01HA

46

Connect electrical connections to transmission control unit, transmission oil temperature sensor (37), main shaft rpm sensor (35) and countershaft rpm sensor (36)

47

Mount compressed air lines to transmission positioner and range group cylinder

48

Install transmission

 See information provided by vehicle manufacturer or transmission 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