Assemble transmission

AR26.10-G-0010OHC

Assemble transmission

22.02.2018

Transmission

715.316 in model 800

1

Compressed-air line

15

Rear section of transmission housing

29

Drive shaft bearing cap

2

Splitter group cylinder

16

Retaining ring

30

Reverse idler shaft

3

Splitter group shift rod

17

Tapered roller bearing outer race

33

Retaining ring

4

Front section of transmission housing

18

Output flange

34

Pulse wheel

5

Screw plug (shift lock)

19

Main shaft

35

Bearing pin

6

Springs

20

Synchronizer cone with synchronizer ring and annular spring

36

Radial shaft sealing ring

7

Catch bolt

21

Sliding sleeve

37

End cover (only on transmission without power take-off)

8

Sliding blocks

22

Drive shaft

B18

Travel and speed rpm sensor (only on transmission without 2-speed transfer case)

9

Oil pipe

23

Electrical lines

B500

Output shaft rpm sensor (transmission with 2-speed transfer case only)

10

Shift fork for splitter group

24

Shift

B501

Main shaft rpm sensor

11

Countershaft

25

Bearing pin

B502

Countershaft rpm sensor

12

Tapered roller bearing outer race

26

Tapered roller bearing outer race

B505

Transmission oil temperature sensor

13

Shift unit

27

Tapered roller bearing outer race

14

Reverse gear

28

Countershaft brake

15

Rear section of transmission housing

38

Screw plug

39

Sealing ring

40

Oil strainer

41

Spring

42

Jack

11

Countershaft

13

Shift unit

15

Rear section of transmission housing

22

Drive shaft

50

Lifting device

43

Holding device

44

Shaft

45

Scale

Installation diagram of screws/bolts in transmission housing rear section (15) at transmission housing front section (4)

A

Screws/bolts (bolt length 62 mm)

B

Screws/bolts (bolt length 83 mm)

C

Screw/bolt (bolt length 94 mm)

 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

 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. 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

Attach rear section of transmission housing (15) to assembly device

 Assembly device

*715589083100

2

Mount tapered roller bearing onto countershaft (11)

AR26.50-G-0007OHC

3

Assemble drive shaft (22)

AR26.50-G-4744OHC

4

Assemble main shaft (19)

AR26.50-G-0426OHC

5

Coat tapered roller bearing outer race (17) with grease and drive into transmission housing rear section (15) from the inside all the way using a suitable drift

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

6

Coat tapered roller bearing outer race (12) with grease and drive into transmission housing rear section (15) from the inside all the way using a suitable drift

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

7

Install reverse idler gear (14) with oiled needle bearing and bush into transmission housing rear section (15) and slide to one side

8

Install main shaft (19), countershaft (11) and shift unit (13) in rear section of transmission housing (15) using lifting device (50)

AR26.50-G-4000-04OHC

 When the shift unit (13) is installed, the reverse idler gear (14) must be pushed to the side.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

Loctite 5203 sealant

*BR00.45-Z-1015-01A

Vaseline

*BR00.45-Z-1015-06A

 Shift fork bearing pin at transmission housing

*BA26.35-N-1001-01HA

 Lifting device

*715589045900

 Clamping device

*315589023100

9

Install oil pipe (9)

10

Center reverse idler gear (14), insert reverse idler shaft (30) and install retaining ring (16)

11

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

AR26.35-G-0002-01OHC

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

12

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

Loctite 5203 sealant

*BR00.45-Z-1015-01A

13

Install front section of transmission housing (4)

AR26.40-G-2470-08OHC



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

14

Screw in bolts around circumference of rear section of transmission housing (15)

 Note installation diagram for bolts (A, B, C).

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

*BA26.40-N-1010-01HA

15

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

16

Coat tapered roller bearing outer races (26, 27) with grease and install up to contact surface using suitable drift

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

17

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

Loctite 5203 sealant

*BR00.45-Z-1015-01A

 Splitter group shift rod lock to transmission housing

*BA26.35-N-1003-01HA

18

Use holding device (43) to fix shift rails of shift unit (13) in neutral position

 The shaft (44) of the holding device (43) must be at zero degrees.

 Holding device

*715589246300

19

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

20

Determine shims for drive shaft (22) and countershaft (11)

AR26.50-G-0410-03OHC


Only use a torque wrench with slave pointer.
Otherwise, the tapered roller bearing outer races (26, 27) 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

 Pliers

*715589013700

 Clamping plates

*715589156300

 Torque wrench

*000589672100

21

Install countershaft brake (28) with determined shim

AR26.50-G-6000OHC

 The oil grooves of brake disks must be aligned.

22

Install bearing cap for drive shaft (29) together with determined shim

AR26.30-G-1020OHC

23

Position transmission so it is horizontal and remove assembly device

24

Install pulse wheel (34)

AR26.19-G-0033OHC

25

Coat sealing surface of new radial shaft sealing ring (36) with synthetic grease and install at output side

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*750589011500

 Adapter

*715589286300

26

Install output flange (18)

AR26.50-G-2000OHC

27

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

28

Install shift piston of splitter group

AR26.35-G-0001OHC

29

Install splitter group cylinder (2)

AR26.18-G-1001OHC

30

Install transmission oil temperature sensor (B505)

 Transmission oil temperature sensor to transmission housing

*BA26.19-N-1005-01HA

31

Install countershaft rpm sensor (B502)

 Bolt, countershaft rpm sensor to transmission housing

*BA26.19-N-1007-01HA

32

Install main shaft rpm sensor (B501)

 Bolt, main shaft rpm sensor to transmission housing

*BA26.19-N-1006-01HA

33.1

Install travel and speed rpm sensor (B18)

Transmission without 2-speed transfer case

 Travel and speed rpm sensor to transmission

*BA26.19-N-1009-01HA

33.2

Install output shaft rpm sensor (B500)

Transmission with 2-speed transfer case

 Output shaft rpm sensor to transmission housing

*BA26.19-N-1013-01HA

34

Install shift mechanism (24)

AR26.60-G-0001OHC

35

Install transmission positioner

Transmission positioner from the company Wabco

AR26.21-G-0006OHD

Transmission positioner from the company Festo

AR26.21-G-0006OHC

36

Install new bush (42) using suitable drift into transmission housing rear section (15)

37

Install spring (41), oil screen (40), new sealing ring (39) and screw plug (38)

 The guide lugs on the oil strainer (40) must point towards the screw plug (38).

 Screw plug, oil strainer

*BA26.56-N-1001-01HA

38.1

Install end cover (37) at rear

Transmission without power take-off

AR26.30-G-3001OHC

38.2

Install power take-off

Transmission with power take-off

Power take-off 121

AR26.45-G-0004OHE

Power take-off 123, power take-off 124

AR26.45-G-0004OHF

Power take-off 125

AR26.45-G-0004OHG

39

Mount electric lines (23) with holders on transmission

 Screw/bolt, bracket to transmission

*BA26.40-N-1009-01HA

40

Install pneumatic central clutch release bearing

Only with Mercedes PowerShift 3

AR25.20-G-0182N

41

Connect electrical connections onto transmission control unit, pneumatic central clutch release bearing, transmission oil temperature sensor (B505), main shaft rpm sensor (B501) and countershaft rpm sensor (B502)

Test and adjustment values for gear set

Number

Designation

Transmission 715.316

BE26.50-N-1003-01HA

Drive shaft bearing pretension

mm

0,0...-0,15

Test and adjustment values for gear set

Number

Designation

Transmission 715.316

BE26.50-N-1004-01HA

Setting tolerance of bearings on countershaft

mm

-0,10...+0,05

 Sensors, transmitters

Number

Designation

Transmission 715.316

BA26.19-N-1005-01HA

Transmission oil temperature sensor to transmission housing

Nm

60

 Sensors, transmitters

Number

Designation

Transmission 715.316

BA26.19-N-1006-01HA

Bolt, main shaft rpm sensor to transmission housing

Nm

10

 Sensors, transmitters

Number

Designation

Transmission 715.316

BA26.19-N-1007-01HA

Bolt, countershaft rpm sensor to transmission housing

Nm

10

 Sensors, transmitters

Number

Designation

Transmission 715.316

BA26.19-N-1009-01HA

Travel and speed rpm sensor to transmission

Nm

40

 Sensors, transmitters

Number

Designation

Transmission 715.316

BA26.19-N-1013-01HA

Output shaft rpm sensor to transmission housing

Nm

40

 Splitter group

Number

Designation

Transmission 715.316

BA26.35-N-1001-01HA

Shift fork bearing pin at transmission housing

Nm

120

 Splitter group

Number

Designation

Transmission 715.316

BA26.35-N-1003-01HA

Splitter group shift rod lock to transmission housing

Nm

30

 Housing

Number

Designation

Transmission 715.316

BA26.40-N-1009-01HA

Screw/bolt, bracket to transmission

M6

Nm

10

M8

Nm

25

M10

Nm

50

 Housing

Number

Designation

Transmission 715.316

BA26.40-N-1010-01HA

Bolt, transmission housing front section to transmission housing rear section

Nm

80

 Gear set, shafts

Number

Designation

Transmission 715.316

BA26.50-N-1003-01HA

Preload of bushings on drive shaft and countershaft for determining shims

Nm

10

 Transmission filter

Number

Designation

Transmission 715.316

BA26.56-N-1001-01HA

Screw plug, oil strainer

Nm

120

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-1015-06A

Vaseline

Friedrich Scharr KG
Liebknechtstr. 50
70565 Stuttgart, Germany
Tel. +49 711 7868-481
Fax +49 711 7868-489
www.scharr.de

BR00.45-Z-1027-06A

Synthetic grease 50 g

A 001 989 32 51 10