Assemble transmission

AR26.10-B-0010TC

Assemble transmission

12.02.16



Assembling

1

Assemble the countershaft (11)

AR26.50-B-4775TB

2

Assemble the input shaft (20)

AR26.50-B-4744TA

3

Install the main shaft (18)

AR26.50-B-0426TA

4

Measure the distance (A) from the sealing surface to the bearing lodging in the center housing (16)

If the distance (A) is 327.5 mm, the shim (17.1) is not installed.

If the distance (A) is 328.5 mm, the shim (17.1) has to be installed under the taper roller bearing cap (17).

5

Place the shim (17.1) on the taper roller bearing cap (17)

 Only if the distance (A) in the center housing (16) is 328.5 mm.

6

Assemble the taper roller bearing cap (12,17) and if necessary with the shim (17.1) in the center housing (16)

 Apply multipurpose grease on the taper roller bearing caps (12, 17).

*BR00.45-B-1056-06A

 Utilize an appropriate mandrel.

7

Mount the reverse gear gearwheel (13) with bearing and bushing

 The long collar of the reverse gear gearwheel (13) must point to the output side.

8

Install the immobilizer device in the oil hole on the main shaft (18)

Immobilizer device

*715589013100

9

Assemble the shift fork of the 3rd/4th gear, then the one of the 1st/2nd gear with the sliding skates with the control bars on the main shaft, engage the reverse gear control bar in the immobilizer device

 Observe the assembly sequence.

10

Place the countershaft (11) in the immobilizer device

11

With the immobilizer device, install the assembly of main shaft (18), and countershaft (11) in the center housing (16)

12

Assemble the pins of the shift forks of the 1st/2nd, 3rd/4th and reverse gear (15)

 Assemble the pins of the shift forks of the 1st/2nd, 3rd/4th and reverse gear (15) with fast drying adhesive.

*BR00.45-B-1006-02A



*BA26.40-B-1006-01D

13

Remove the immobilizer device

14

Assemble the synchronizer cone with the synchronizer ring and annular spring (19)

 The long collar must point to the output side.

15

Assemble the input shaft (20)

 Move the countershaft (11) aside and apply multipurpose grease on the taper roller bearing (pilot bearing).

*BR00.45-B-1056-06A

16

Center the reverse gear gearwheel (13) and assemble the reverser gear shaft (23)



*BA26.40-B-1007-01D

17

Assemble the oil tube (10)

18

Assemble the shift fork of the split group (9) with the sliding skates (8)

19

Place the centering mandrel on the oil tube (10)

 Centering mandrel

*715589031500

20

Place the guide pins in the front housing (7)



Guide pin for installing the split group

WF58.50-B-3100-01A

21

Fit the front housing (7) on the center housing (16)

 Apply sealing compound on the sealing surfaces.

*BR00.45-B-1029-02B

The control bars must slide on the guide of the front housing (7).

22

Assemble the lock (6) on the oil tube (10) and remove the centering mandrel from the oil tube (10)

23

Remove the guide pin from the front housing (7) and place the fastening bolts of the front housing (7)

 Observe the different bolt lengths.



*BA26.40-B-1004-01D

24

Assemble the taper roller bearing caps (2, 4)

 Apply multipurpose grease on the taper roller bearing caps (2, 4).

*BR00.45-B-1056-06A

 Utilize an appropriate mandrel.

25

Install the radial seal and the guide bushing of the control rod of the split group

AR26.35-B-1000-03TA

 Mandrel

*714589051500

Synthetic grease

*BR00.45-B-1021-06A

26

Install the split group's control rod

 The shift fork of the split group (9) has to engage in the recess of the control rod.

AR26.35-B-1000TA

27

Assemble shift fork pin of the split group (22)

 Apply fast drying adhesive on the shift fork pin of the split group (22).

*BR00.45-B-1006-02A



*BA26.35-B-1001-01B

28

Assemble the countershaft cover (1) and the input shaft cover (3)

AR26.30-B-1010TA

29

Place the gearbox in the horizontal

30

Determining the compensating washer for the split group's shift piston

AR26.35-B-1000-01A

*BE26.35-B-1001-01A

31

Lift out the control rod with the assembly tool



Assembly tool to install the control rod of the split group

WF58.50-B-2635-01A

32

Assemble the double groove seal and the shift piston

 Apply synthetic grease on the double groove seal.

*BR00.45-B-1021-06A

Lock the shift piston with fast drying adhesive.

*BR00.45-B-1010-02A



*BA26.35-B-1002-01B

 Fitting wrench

*715589020700

33

Determining the compensating washer for the split group's command cylinder

AR26.35-B-1000-02TA

*BE26.35-B-1002-01A

 Inside puller

*000589303300

 Counter-support

*000589343300

34

Assemble the control unit (21)

Vehicles with code (GS1) "manual" gearbox actuation.

AR26.60-B-0001TE

Vehicles with code (GS2), electro-pneumatic gear shifting.

AR26.60-B-0001TB

35

Assemble the range group (14)

AR26.31-B-3201TA

36

Install the range group (14)

AR26.31-B-3102TA

37

Install the neutral sensor (S9)

 Only vehicles with code (GS1) "manual" gearbox actuation.



*BA26.19-B-1010-01B

38

Install the oil temperature sensor (B47)



*BA26.19-B-1006-01B

39

Install the countershaft revs sensor (B3)



*BA26.19-B-1007-01B

40

Connect the electric wires on the connectors and supports

41

Install the clutch throw-out lever



*BA25.20-B-1001-01L

Número

Denominação

Gearboxes 715.504, 715.517, 715.527, 715.564

BE26.35-B-1001-01A

Adjusting measurement of the split group shift piston

mm

0,3...0,5

BE26.35-B-1002-01A

Adjusting measurement of the split group shift cylinder

mm

0,4...0,5

Número

Denominação

Chassis 958.0, 958.1

Chassis 934.2, 958.2, 958.4

BA25.20-B-1001-01L

Fork in the gearbox

M12

Nm

90

90

M10

Nm

60

60

Número

Denominação

Gearboxes 715..., with mechanical speed command”

Gearboxes 715..., with “EPS” speed command

BA26.19-B-1006-01B

Oil temperature transmitter in the gearbox

Nm

60

60

BA26.19-B-1007-01B

Over-speed switch in the gearbox

Nm

40

40

BA26.19-B-1010-01B

Neutral position switch

Nm

60

-

Número

Denominação

Gearboxes 715.504/517/527

BA26.35-B-1001-01B

Selector fork retaining pin in the gearbox

Nm

120

BA26.35-B-1002-01B

Fastening of the split group's shift piston

With special tool

Nm

90

without special tool

Nm

95

Número

Denominação

Gearboxes 715.50/51/52, 715.56, 715.540

BA26.40-B-1004-01D

Housing on the center part of the gearbox

Nm

80

BA26.40-B-1006-01D

Support pins (threaded) of the gearbox selection forks

Nm

120

BA26.40-B-1007-01D

Reverse gear retainer plate on the gearbox

Nm

60

Número

Denominação

Número de pedido

BR00.45-B-1006-02A

Adhesive mass Loctite 242

A 003 989 31 71

BR00.45-B-1010-02A

Fast-drying adhesive

A 002 989 93 71

Número

Denominação

Número de pedido

BR00.45-B-1029-02B

Surfaces sealing product Loctite 5203

Henkel Loctite

Número

Denominação

Número de pedido

BR00.45-B-1021-06A

Synthetic grease

A 001 989 32 51

BR00.45-B-1056-06A

Vaseline - DBL 6850.00

A 000 989 15 51