Assembling transmission main shaft

AR26.50-G-0426A

Assembling transmission main shaft

31.5.06



Assembly

1

Check wear limits between synchronizer cones and sliding sleeves

AR26.50-G-0420-12A

*BE26.50-N-1004-01I



*WH58.30-Z-1004-12A



*WH58.30-Z-1004-12A

2

Slide 2nd gear wheel (25) with needle roller bearing (24) onto the main shaft (23)

 Lubricate needle roller bearing (24) and thrust collar of gear wheel for 2nd. gear (25).

3

Mount synchronizer ring (26) onto gear wheel for 2nd gear (25)

4

Insert annular spring (28) into synchronizer cone (27) and press into synchronizer ring (26)

 Check annular spring (28) for wear and replace if necessary. Lubricate annular spring (28) and cones.

5

Push on synchronizer body (30) and install locking ring (31) without play

 If necessary install circlip (31) of a different thickness

*BE26.50-N-1001-01I

6

Install sliding sleeve (29)

 The long chamfer must face the output end.

7

Insert annular spring (32) into synchronizer cone (33) and press into synchronizer ring (35)

 Check annular spring (32) for wear and replace if necessary. Lubricate annular spring (32) and cones.

8

Install synchronizer ring (35) with synchronizer cone (33)

9

Push 1st gear wheel (36) with needle bearing (34) onto main shaft (23)

 Oil needle roller bearing (34) and thrust collar of 1st gear wheel (36).

10

Push reverse gear synchronizer body (37) onto mainshaft (23)

 The collar should point to the 1st gear wheel (36).

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

11

Heat bush (41) to approx. 100 °C and push on

 Adjust bushing (41) to be free of axial play.



*WH58.30-Z-1002-28A

12

Install sliding sleeve (40).

 The rounded teeth on the sliding sleeve (40) should be toward the output end.

13

Install reverse gear shift fork (39) with sliding blocks (38)

 The cam (arrow) and reverse gear shift fork (39) must point towards the output end.

14

Push reverse gear wheel (43) with needle bearing (42) onto main shaft (23)

 Lubricate needle roller bearing (42) and thrust collar of reverse gear gearwheel (43).

15

Heat tapered roller bearing (44) to approx. 100 °C and push on

 Adjust tapered roller bearing (44) to zero axial play.



*WH58.30-Z-1002-28A

16

Install spacer ring (45), sun gear (46) and circlip (47)

 Spacer ring (45) only with tapered roller bearing (44) without collar.

17

Turn main shaft (23) around and clamp securely

 Use protective jaws to prevent damage to the main shaft (23).

18

Slide 3rd gear wheel (21) with needle roller bearing (22) onto the main shaft (23)

 Oil the needle roller bearings (22) and the thrust collar of the 3rd gear wheel (21).

19

Mount synchronizer ring (20) on the 3rd gear wheel (21)

20

Insert annular spring (19) into synchronizer cone (18) and press into synchronizer ring (20)

 Check annular spring (19) for wear and replace if necessary. Lubricate annular spring (19) and cones.

21

Push on synchronizer body (17), insert circlip (16) so there is no play

 The long collar must point towards the output. If necessary install circlip (16) of a different thickness

*BE26.50-N-1001-01I

22

Heat tapered roller bearing (12) to approx. 100 °C and push on

 Adjust tapered roller bearing (12) to zero axial play and grease with multipurpose grease.



*WH58.30-Z-1002-28A

*BR00.45-Z-1017-06A

23

Install sliding sleeve (15).

 The long chamfer must face the output end.

24

Insert annular spring (14) into synchronizer cone (13) and press into synchronizer ring (11)

 Check annular spring (14) for wear and replace if necessary. Lubricate annular spring (14) and cones.

25

Install synchronizer ring (11) with synchronizer cone (13)

26

Install constant mesh gear 2 (10)

27

Heat tapered roller bearing (6) to approx. 100 °C and push on

 After sliding on grease the rollers of the tapered roller bearing (6) with multipurpose grease.



*WH58.30-Z-1002-28A

*BR00.45-Z-1017-06A

28

Determine shim (4) for main shaft

 Shim (4) for adjusting the axial play of the constant mesh gearwheel 2 (10).

AR26.50-G-0420-11A

*BE26.50-N-1002-01I



*001589532100



*652589003321



*652589003323



*714589042100



*715589002100



*715589005900



*715589023300



*715589032100



*715589113400



*715589123400



*715589153400

29

Install shims (4) determined and spacer ring (5)

 Spacer ring (5) only with tapered roller bearing (6) without collar.

30

Heat tapered roller bearing (3) to approx. 100 °C and push on

 Adjust tapered roller bearing (3) to zero axial play.



*WH58.30-Z-1002-28A

31

Install thrust washer (2) and locknut (1)

 The locknut (1) has a left-hand thread.
Thrust plate (2) only with locknut (1) without collar.



*BA26.50-N-1001-01M

32

Support with piece of wood and stake lock nut (1)

 Not with microencapsulated locknut (1).

33

Mount synchronizer ring (9) on constant mesh gearwheel 2 (10)

34

Insert annular spring (7) into synchronizer cone (8) and press into synchronizer ring (9)

Check annular spring (7) for wear and replace if necessary. Lubricate annular spring (7) and cones.

35

Install reverse gear shift rail (49) and locking plate (48)

Number

Designation

Transmission 715.501/511 with code GS3 and code IY2
in model 000.001

BE26.50-N-1001-01I

Axial play of locking rings

mm

< 0.08

BE26.50-N-1002-01I

Tapered roller bearing end play for constant mesh gear 2

mm

0,02 to 0,08

BE26.50-N-1004-01I

Wear limit between synchronizer cone and sliding sleeve

mm

< 0,3

Number

Designation

Transmission 715.501/511 with code GS3 and code IY2
in model 000.001

BA26.50-N-1001-01M

Locknut, pilot bearing to mainshaft

Nut for caulking

Nm

300

Nut with micro-encapsulation

Nm

340

Number

Designation

WH58.30-Z-1004-12A

Feeler gauge

WH58.30-Z-1002-28A

Heating plate

Number

Designation

Order number

BR00.45-Z-1017-06A

MB multipurpose grease

A 001 989 34 51 11