Remove/install range group

AR26.31-G-3100AE

Remove/install range group

04.03.2019

Transmission

715.537/538/539 in model 800

1

Transmission

2

Catch bolt

3

Spring

4

Screw plug

6

Planetary gear set with shift mechanism

7

Carrier ring

8

Oil pump

9

End cover

10

Output flange

11

Range group

13

Spring

14

Oil strainer

15

Sealing ring

16

Screw plug

44

Compressed-air line

45

Compressed-air line

46

Compressed air connections

B18

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

11

Range group

30

Bracket

31

Lifting eye

32

Wood

17

Drift 03

18

Threaded hole

19

Extraction bolt

20

Extraction bolt

Only for vehicles with transmission cooling

12

Oil lines

25

O-rings

50

Detaching tool

A

Arrow direction

B

Arrow direction

 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

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



Remove

1

Drain fluid from transmission.



AP26.00-G-2601OH

2.1

Remove end cover (9).

On transmissions without power take-off

AR26.30-G-3001AD

2.2

Remove power take-off.

On transmissions with power take-off

Power take-off 121

AR26.45-G-0004ADA

Power take-off 123, 124

AR26.45-G-0004ADB

Power take-off 125

AR26.45-G-0004ADC

Power take-off 131

AR26.45-G-0004ADD

Power take-off 135

AR26.45-G-0004ADE

3

Remove oil pump (8).

AR26.55-G-3000AE

4

Remove oil lines (12).

Only on transmission (1) with transmission oil cooling.

 Collect escaping oil in a suitable vessel.
To release, push the detaching tool (50) first in the direction of arrow (arrow A) and then in the direction of arrow (arrow B).
Then detach the oil lines (12).

5

Remove propeller shaft from output flange (10).

6

Remove retarder.

Only on transmissions (1) with secondary coolant-retarder.

AR43.30-G-0002N

7

Remove compressed-air lines (44, 45) from range group cylinder.

8

Remove compressed-air lines (46) from range group cylinder.

Only on transmissions (1) with power take-off.

9

Unscrew screw plug (4) and remove spring (3).

 The screw plug (4) is spring-loaded.

10

Pull out catch bolt (2) approx. 30 mm.

11

Disconnect electrical connector from travel and speed rpm sensor (B18).

Only on body without 2-speed transfer case.

12

Remove electrical wiring harness from range group (11).

13

Remove holder (30) from transmission (1) and support from underneath using a piece of wood (32).

14

Unscrew screw plug (16) and remove oil screen (14) and spring (13).

15

Remove screws around circumference of range group (11).

16.1

Attach lifting eye (31) to housing of range group (11).

When removing the range group (11) upward.

 Lifting eye

*715589004000

16.2

Attach transmission plate to pit hoist and secure to housing of range group (11) using suitable means.

When removing the range group (11) downward.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 05 80 00 Pit lift

WS00.00-P-0248B

17

Install drift 03 (17).

 Drift

*715589091500

18

Pull off range group (11) evenly using puller bolts (19, 20) via the three threaded holes (18).

 Pry carrier ring (7) off both lower bolts using a suitable tool.

 Puller screws

*715589143300

19

Disassemble range group (11).

Only if the range group (11) is to be repaired.

AR26.31-G-3200AE

20

Remove drift 03 (17).



Install

21

Assemble range group (11).

Only if the range group (11) has been disassembled.

AR26.31-G-3200AE

22

Clean sealing surfaces on transmission (1) and range group (11) and coat with sealant.

Loctite 5203 sealant

*BR00.45-Z-1015-01A

23

Install drift 03 (17).

 Drift

*715589091500

24

Place range group (11) on transmission (1).

 By turning the output flange (10) mesh the toothing on the sun gear and in the planetary gear set with the shifting device (6).

25

Align carrier ring (7) with centering pin on transmission (1) and push in range group (11) up to contact.

26

Remove drift 03 (17).

27.1

Remove lifting eye (31) from range group (11).

If range group (11) is installed from above.

 Lifting eye

*715589004000

27.2

Remove housing of range group (11) from transmission plate and pit hoist.

If range group (11) is installed from below.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 05 80 00 Pit lift

WS00.00-P-0248B

28

Screw in screws around circumference of range group (11).

 Pay attention to different lengths of bolts.

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

*BA26.40-N-1002-01HA

29

Install spring (13) and oil screen (14) and screw in screw plug (16) tightly.

 Replace sealing ring (15).
The guide lugs on the oil strainer (14) must point toward the screw plug (16).

 Screw plug, oil strainer

*BA26.56-N-1001-01HA

30

Install oil pump (8).

AR26.55-G-3000AE

31

Insert catch bolt (2) with spring (3) and tighten screw plug (4).

 Range group shift rod lock to transmission housing

*BA26.31-N-1003-01HA

32

Attach holder (30) to transmission (1).

 Screw/bolt, bracket to transmission

*BA26.40-N-1009-01HA

33

Secure electrical wiring harness along original fastening points on range group (11).

34

Connect electrical connector to travel and speed rpm sensor (B18).

Only on vehicles without 2-gear transfer cases.

35

Attach compressed-air lines (44, 45) to range group cylinder.

36

Attach compressed-air lines to compressed-air connections (46) of range group cylinder.

Only on transmissions (1) with power take-off.

37

Install oil lines (12).

Only on transmissions (1) with transmission oil cooling.

 Replace O-rings (25).

38

Install retarder.

Only on transmissions (1) with secondary coolant-retarder.

AR43.30-G-0002N

39

Attach propeller shaft to output flange (10).

 Bolt/nut, propeller shaft to flange connection

*BA41.10-N-1002-01F

40.1

Install end cover (9).

On transmissions without power take-off

AR26.30-G-3001AD

40.2

Install power take-off.

On transmissions with power take-off

Power take-off 121

AR26.45-G-0004ADA

Power take-off 123, 124

AR26.45-G-0004ADB

Power take-off 125

AR26.45-G-0004ADC

Power take-off 131

AR26.45-G-0004ADD

Power take-off 135

AR26.45-G-0004ADE

41

Pour in transmission oil and correct transmission oil level.



AP26.00-G-2601OH

 Range group

Number

Designation

Transmission 715.537/538/539

BA26.31-N-1003-01HA

Range group shift rod lock to transmission housing

Size 24

Nm

-

Size 32

Nm

100

 Housing

Number

Designation

Transmission 715.537/538/539

BA26.40-N-1002-01HA

Bolt, transmission housing rear section to transmission housing center section

Nm

80

 Housing

Number

Designation

Transmission 715.537/538/539

BA26.40-N-1009-01HA

Screw/bolt, bracket to transmission

M6

Nm

10

M8

Nm

25

M10

Nm

50

 Transmission filter

Number

Designation

Transmission 715.537/538/539

BA26.56-N-1001-01HA

Screw plug, oil strainer

Nm

120

 Propeller shaft

Number

Designation

Model 800

BA41.10-N-1002-01F

Bolt/nut, propeller shaft to flange connection

M10

Nm

-

M12

Nm

100

M14

Nm

160

M16

Nm

200

Repair materials

Number

Designation

Order number

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10