Assemble main shaft

AR26.50-G-0428AC

Assemble main shaft

23.01.2018

Transmission

715.067 in model 800

1

Synchronizer ring

17

Synchronizer cone

33

Synchronizer cone

2

Synchronizer cone

18

Synchronizer ring

34

Synchronizer ring

3

Sliding sleeve

19

Synchronizer cone

35

Synchronizer cone

4

Retaining ring

20

Sliding sleeve

36

Synchronizer body

5

Synchronizer body

21

Retaining ring

37

Retaining ring

6

Compression spring

22

Synchronizer body

38

Sliding sleeve

7

Thrust piece

23

Synchronizer cone

39

Synchronizer cone

8

Synchronizer ring

24

Synchronizer ring

40

Synchronizer ring

9

Synchronizer cone

25

Synchronizer cone

41

Synchronizer cone

10

6th gear gearwheel

26

Driver

42

Driver

11

Needle roller bearing

27

3rd gear wheel

43

Needle roller bearing

12

Retaining ring

28

Needle roller bearing

44

1st gear wheel

13

Thrust plate

29

Main shaft

45

Synchronizer body

14

4th gear wheel

30

Needle roller bearing

46

Retaining ring

15

Driver

31

2nd gear wheel

47

Needle roller bearing

16

Needle roller bearing

32

Driver

48

Reverse gearwheel

Shown on 3rd/4th gear synchronizer unit

20

Sliding sleeve

22

Synchronizer body

A

Marking (3x around circumference of component)

B

Cutout with straight tooth (3x around circumference of component)

Shown on 1st/2nd gear synchronizer unit

36

Sliding sleeve

38

Synchronizer body

A

Marking (3x around circumference of component)

B

Cutout with straight tooth (3x around circumference of component)

 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

 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.
Deburr repair panels.

AS00.00-Z-0017-01A

 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



Assemble

1

Soak all synchronizer rings (1, 8, 18, 24, 34, 40) in transmission oil


Before installation, all synchronizer rings (1, 8, 18, 24, 34, 40) must be soaked for at least 8 hours in cold transmission oil or for 10 minutes in hot transmission oil (approx. 70 °C).
Otherwise, an exact measurement of the axial play is not possible.

2

Clamp main shaft (29) at output end to gearing of synchronizer body (36)

 Clamping device

*315589023100

3

Lubricate and install needle bearing (28) and thrust collar of gearwheel for 3rd gear (27)

4

Place driver (26) with chamfered teeth at top onto gearwheel for 3rdgear (27)

5

Install synchronizer cone (25)

6

Lubricate synchronizer ring (24) and install with synchronizer cone (23)

7

Slide on synchronizer body (22) and insert retaining ring (21)

 The wide collar of the synchronizer body (22) must face towards the drive side.

8

Check end play between retaining ring (21) and synchronizer body (22)

AR26.50-W-0426-03NA

 If necessary, fit retaining ring (21) of appropriate thickness.

Axial play at retaining ring of main shaft

*BE26.50-N-1008-01NA

9

Install sliding sleeve (20)

 For sliding sleeves (20) with markings (A)
The identification groove on the sliding sleeve (20) must face toward the output end. The markings (A) on the sliding sleeve (20) and the markings (A) on the synchronizer body (22) must be on the same side and opposite each other.

 For sliding sleeves (20) without markings (A)
The identification groove on the sliding sleeve (20) must face toward the output end. The cutouts with straight tooth (B) on the sliding sleeve (20) and the rectangular cutout on the synchronizer body (22) must mesh on the correct side as only then can the component parts be installed.

10

Insert thrust pieces (7) with compression springs (6) into cutouts on synchronizer body (22)

 To do so, shift sliding sleeve (20) through the gear to the gear for the 3rd gear (27).

11

Install synchronizer cone (19)

12

Lubricate synchronizer ring (18) and install with synchronizer cone (17)

13

Place driver (15) with chamfered teeth at bottom onto synchronizer body (22)

14

Lubricate and install needle bearing (16) and thrust collar of gearwheel for 4th gear (14)

15

Heat up thrust plate (13) to approx. 80 °C and install

 The ground side of the thrust plate (13) must face towards the gear for the 4th gear (14).

16

Install retaining ring (12)

17

Shift sliding sleeve (20) into neutral position

18

Check axial play between retaining ring (12) and thrust plate (13)

AR26.50-W-0426-03NA

 If necessary, install a retaining ring (12) of appropriate thickness.

Axial play at retaining ring of main shaft

*BE26.50-N-1008-01NA

19

Lubricate and install needle bearing (11) and thrust collar of gearwheel for 6th gear (10)

20

Lubricate and install synchronizer ring (8)

21

Install synchronizer cone (9)

22

Install synchronizer body (5)

 The high collar of the synchronizer body (5) must face towards the output end.

23

Install retainer ring (4)

24

Check end play between retaining ring (4) and synchronizer body (5)

AR26.50-W-0426-03NA

 If necessary, install a retaining ring (4) of appropriate thickness.

Axial play at retaining ring of main shaft

*BE26.50-N-1008-01NA

25

Install sliding sleeve (3)

26

Insert thrust pieces (7) with compression springs (6) into cutouts on synchronizer body (5)

 To do so, shift sliding sleeve (3) through gear to gear for 6th gear (10).

27

Install synchronizer ring (1) and synchronizer cone (2)

28

Secure synchronizer rings (1 and 8) on gearwheel for 6th gear (10) using retaining springs

 Retaining spring

*715589026300

29

Shift sliding sleeve (3) into neutral position

30

Remove main shaft (29) and insert on drive side into mounting plate

 Support plate

*715589316300

31

Lubricate and install needle bearing (30) and thrust collar of gearwheel for 2nd gear (31)

32

Install synchronizer cone (33)

33

Lubricate synchronizer ring (34) and install with synchronizer cone (35)

34

Position driver (32) with chamfered teeth toward output

35

Install synchronizer body (36)

 The high collar of the synchronizer body (36) must face towards the drive side.

36

Install retaining ring (37)

37

Check end play between retaining ring (37) and synchronizer body (36)

AR26.50-W-0426-03NA

 If necessary, install a retaining ring (37) of appropriate thickness.

Axial play at retaining ring of main shaft

*BE26.50-N-1008-01NA

38

Install sliding sleeve (38)

 For sliding sleeves (38) with markings (A)
The identification groove on the sliding sleeve (38) must face towards the output end. The markings (A) on the sliding sleeve (38) and the markings (A) on the synchronizer body (36) must be on the same side and opposite each other.

 For sliding sleeves (38) without markings (A)
The identification groove on the sliding sleeve (38) must face towards the output end. The cutouts with straight tooth (B) on the sliding sleeve (38) and the rectangular cutout on the synchronizer body (36) must mesh on the correct side as only then can the component parts be installed.

39

Insert thrust pieces (7) with compression springs (6) into cutouts on synchronizer body (36)

 To do so, shift sliding sleeve (38) through gear to gear for 2nd gear (31).

40

Install synchronizer cone (39)

41

Lubricate synchronizer ring (40) and install with synchronizer cone (41)

42

Position driver (42) with chamfered teeth toward drive

43

Lubricate and install needle bearing (43) and thrust collar of gearwheel for 1st gear (44)

44

Heat up synchronizer body (45) to approx. 80 °C and install

45

Shift sliding sleeve (38) into neutral

46

Insert retaining ring (46)

47

Check end play between retaining ring (46) and synchronizer body (45)

AR26.50-W-0426-03NA

 If necessary install retaining ring (46) of a different thickness.

Axial play at retaining ring of main shaft

*BE26.50-N-1008-01NA

48

Install needle bearing (47) and gearwheel for reverse gear (48)

 The rounded off teeth from the gear of the reverse gear (48) must face towards the rounded off teeth on the synchronizer body (45).

49

Assemble transmission

AR26.10-G-0010AC

Test and adjustment values for gear set

Number

Designation

Transmission 715.067

BE26.50-N-1008-01NA

Axial play at retaining ring of main shaft

mm

0,00...0,07