Assemble transmission

AR26.10-G-0010BB

Assemble transmission

27.2.12



Assemble

1

Assemble countershaft (11)

AR26.50-G-4775BB

2

Assemble (20) drive shaft

AR26.50-G-4744D

3

Assemble main shaft (18)

AR26.50-G-0426C

4

Install tapered roller bearing outer races (12, 17) in the transmission housing center part (16)

 Use a suitable drift.
The tapered roller bearing outer races (12, 17) must be installed in the center section of the transmission housing (16) from the inside, and inserted all the way against their seats.

Lubricate tapered roller bearing outer races (12, 17) with multipurpose grease.

*BR00.45-Z-1017-06A

5

Install reverse idler gear (13) with bearing and bush

 Check bearing and bush for wear and replace if necessary.

The long collar of the reverse gear (13) must point towards the output.

6

Install retainer (26) on oil passage in main shaft (18)



*715589013100

7

Install the 3rd/4th gear shift fork as well as the 1st/2nd gear shift fork together with the sliding blocks and shift rails onto the main shaft and hook in the reverse gear shift rail onto the holding device (26)

 Observe correct sequence.



*715589013100

8

Attach countershaft (11) to the retainer (26)



*715589013100

9

Use retainer to insert main shaft (18), countershaft (11) and shift fork with retainer (26) into the center section of the transmission housing (16)



*715589013100

10

Install bearing bolt for 1st/2nd, 3rd/4th shift fork and reverse gear (15)

 Insert bearing bolt (15) with sealing compound.



*BA26.40-N-1003-01N

*BR00.45-Z-1133-02A

11

Remove retainer (26)



*715589013100

12

Install sliding sleeve (19).

 The long collar must point towards the output.

13

Install drive shaft (20)

 Push the countershaft (11) to one side. Apply multipurpose grease to tapered roller bearings (pilot bearing).

*BR00.45-Z-1017-06A

14

Align reverse idler gear (13) and insert reverse idler shaft (23)

15

Install reverse idler shaft retainer (24) and secure with bolt (25)



*BA26.40-N-1006-01N

16

Install oil pipe (10)

17

Install splitter group shift fork (9) with sliding blocks (8)

18

Insert alignment punch into the oil pipe (10)



*715589031500

19

Screw guide bolts into the front section of transmission housing (7)



Guide bolt for installing range group

WF58.50-N-3100-01A

20

Fit front section of transmission housing (7) on center section of transmission housing (16)

 Coat sealing surfaces with sealing compound. The shift rails should slide into the guideways in the transmission housing's front section (7).

*BR00.45-Z-1015-01A

21

Unscrew bolts (27) around circumference of center section of transmission housing (16)

 Remove guide studs from the front section of the transmission housing (7)

Pay attention to different lengths of bolts.



*BA26.40-N-1001-01N

22

Install circlip (6) on oil pipe (10) and remove alignment punch from oil pipe (10)



*715589031500

23

Install tapered roller bearing outer races (2, 4) as far as the stop

 Use a suitable drift.

Lubricate tapered roller bearing outer races (2, 4) with multipurpose grease.

*BR00.45-Z-1017-06A

24

Install radial shaft seal and pilot bushing for shift rod of splitter group

AR26.35-G-1000-03B

*BE26.35-N-1003-01B



*116589084300

Depth gage

*BR00.45-Z-1027-06A



Adapter for removing guide bush in front section of transmission housing

WF58.50-N-1000-01A

25

Install shift rod of splitter group

 The shift fork (9) must engage in the recess in the shift rod.

AR26.35-G-1000B

26

Install bearing bolt for shift fork of splitter group (22)

 Install bearing pins for splitter group shift forks (22) with sealant.



*BA26.40-N-1003-01N

*BR00.45-Z-1133-02A

27

Install countershaft bearing cover (1) and input shaft bearing cover (3)

AR26.30-G-1010B

28

Determine shim for shift piston of splitter group

AR26.35-G-1000-01B

*BE26.35-N-1001-01B

Depth gage

29

Extract shift rod for splitter group with assembly tool



Assembly tool for installing splitter group shift rod

WF58.50-N-2635-01A

30

Install rubber sealing ring and shift piston for splitter group

 Coat rubber sealing ring with synthetic grease.

Secure shift piston with locking agent.



*715589000700

*BR00.45-Z-1008-02A

*BR00.45-Z-1027-06A

31

Determine shim for cylindrical actuator of cascade box

AR26.35-G-1000-02B

*BE26.35-N-1002-01B



*000589303300



*000589343300

Depth gage

*BR00.45-Z-1027-06A

32

Install shift mechanism (21)

AR26.60-G-0001B

33

Drive back the dowel pins from the center section of the transmission housing (16) into the front section of the transmission housing(7)

34

Assemble range group (14)

AR26.31-G-3201B

35

Install range group (14)

 Observe torque specifications when installing range group (14) in the center section of the transmission housing (16).

AR26.31-G-3102B

36

Install neutral position switch (S9)



*BA26.19-N-1006-01J

37

Install transmission oil temperature sensor (B47)



*BA26.19-N-1002-01J

38

Install rpm sensor for countershaft (B3)



*BA26.19-N-1003-01J

39

Install clutch release lever

AR25.20-G-0200B

40

Fill transmission with gear oil

 To prevent damage to the transmission, always use gear oils contained in the Specifications for Operating Fluids: 



Gear oils

sheet 235.01

BB00.40-P-0235-01A



Gear oils

sheet 235.05

BB00.40-P-0235-05A

Number

Designation

Transmission 715.521/560 in model 000.001

BE26.35-N-1001-01B

Adjustment dimension for gearshift piston of cascade box

mm

0.3...0.5

BE26.35-N-1002-01B

Adjustment dimension for splitter box shift cylinder

mm

0.4...0.5

BE26.35-N-1003-01B

Splitter box guide bushing recess

mm

3.7 to 4.7

Number

Designation

Transmission
715.521/560 in model 000.001

BA26.19-N-1002-01J

Transmission oil temperature sensor to transmission housing

Nm

60

BA26.19-N-1003-01J

Rpm sensor (countershaft) to transmission housing

Nm

40

BA26.19-N-1006-01J

Neutral position switch to transmission housing

Nm

60

Number

Designation

Transmission 715.521/560
in model 000.001

BA26.40-N-1001-01N

Front section of transmission housing to center section of transmission housing

Nm

70

BA26.40-N-1003-01N

Bearing bolt to shift fork (main shaft)

Nm

120

BA26.40-N-1006-01N

Retaining panel of reverse shaft to transmission housing

Nm

60

Number

Designation

Order number

BR00.45-Z-1133-02A

Loctite 243

A 613 989 09 71

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1008-02A

Quick-acting adhesive, Loctite 270

A 002 989 93 71

BR00.45-Z-1017-06A

MB multipurpose grease

A 001 989 34 51 11

BR00.45-Z-1027-06A

Synthetic grease 50 g

A 001 989 32 51 10