Assemble transmission

AR26.10-B-0010DT

Assemble transmission

04.08.2020

Transmission

712.820/830 in model 963

 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

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Assemble

1

Clean the transmission housing and all the parts

 Completely remove residues of oil, gasket and chemical lock from inside and outside of the transmission housing and its components.

2

Clean the bearings


When drying the bearing with compressed air, never direct the jet to rotate the bearing at high speed.
This may damage the bearing.

 Use a proper cleaning product.

3

Check the front, central and rear section of the housing and covers

 Check for cracks, wear or other conditions that could cause oil leakage or faults.

 Inspect contact surfaces, bearing holes, for burrs or notches.

 Assembly: Oil seals should be replaced with new ones. Lubricate the oil retainers.

 Assembly: Lubricate all gears, bearings and other components subjected to friction, in order to prevent damage during the first revolutions.

4

Check gears for wear

If the gear teeth have worn or cracked areas:



Replace the damaged gear by a new one.

5

Check shafts for any kind of wear

If the shafts show signs of wear, damaged splines or warping:



Replace the damaged shaft by a new one.

6

Check the bearings

 Check every rollers for wear, chippings or cracks. After inspection, bathe the bearing in oil and wrap it with a clean, lint-free cloth or paper, to protect it until the moment of assembly.

If the bearing shows any defect or wear:



Replace this with a new one.

 If the tapered bearing is replaced with a new one, the respective bearing cap on the transmission housing will also have to be replaced.

7

Place the front of the housing in an upright position

 Place the housing in an appropriate support. Clutch side down.

8

Install the countershaft and drive shaft bearing shells

 Secure them to the housing, to prevent them from falling.

9

Assemble the drive shaft

AR26.50-B-4744DT

10

Assemble the counter shaft

AR26.50-B-4775DT

11

Assemble the main shaft

AR26.50-B-0420DT

12

Install the splitter group drive rod

13

Install the pin, the two springs, and the splitter group drive rod screw plug

 Ensure correct spring and pin position.

  Splitter group rod threaded plug

*BA26.10-B-1032-01MB

14

Install the transmission shafts

AR26.50-B-0009-02DT

 Ensure correct alignment between the shafts and correct installation of the drive fork of the splitter group with the drive rod.

15

Install the splitter group drive yoke threaded pins

  Fork guide-pin

*BA26.10-B-1014-01MB

16

Install the control bars with shift forks

AR26.60-B-0021DT

 Make sure that the control bars and shift forks are correctly installed.

17

Install the oil pipe

 The oil pipe is secured by the clutch side through a retaining ring. Use a new retaining ring.

18

Install the splitter group sensor pin plain bearing

AR26.60-B-0018DT

19

Install the shifter

AR26.60-B-0001DT

 Make sure that the drifter is correctly fitted with the control bars. The drifter must be in neutral.

20

Apply seal to the contact surface of the idler housing with the front housing

Loctite 5203 surface sealant

*BR00.45-Z-1129-02A

21

Install the idler housing into the front housing

 Slowly lower and align the idler housing with the front housing guide pins, the oil pipe, and the gear change unit sidebars. Use the mandrel assembly to align the housings.

 Use an appropriate lifting equipment to lift the idler housing.

  Housing screw

*BA26.10-B-1020-01MB

 Drift

*715589091500

22

Install the shift fork threaded pins

  Fork guide-pin

*BA26.10-B-1014-01MB

23

Install the main shaft rpm sensor

AR26.19-B-0500DT

24

Install the counter shaft rotation sensor

AR26.19-B-0018DT

25

Install the oil temperature sensor

AR26.19-B-0017DT

26

Install reverse gear switch

 Make sure that the reverse idler gear shaft is centered with the bearing and needle bearing. Position the reverse gear shaft and tap with a suitable mandrel.

 Ensure correct position of reverse idler gear.

  Reverse gear screw

*BA26.10-B-1026-01MB

27

Install the oil pan with the oil screen

AR26.10-B-0004DT


Whenever possible, replace the oil sieve with a new one.
If the oil sieve is saturated with metal particles or used oil residues, there will be contamination of the new gearbox oil (), which can cause internal components to wear out.

 Apply seal to the whole oil pan surface with the housing.

Loctite 5203 surface sealant

*BR00.45-Z-1129-02A

28

Install the range group synchronizer gear

 Pay attention to the correct position of the synchronizer gear.

 Use a new retaining ring. Make sure the snap ring is securely installed in its housing.

29

Install the range group sun gear

AR26.50-B-3103-01DT


Ensure correct installation of sun gear.
If the sun gear becomes loose, it can cause serious damage to the transmission.

30

Mount the drive rod range group piston

 Mount the retainer in a vise. Be careful not to damage the drive rod.

  Range group piston in the control rod

*BA26.10-B-1009-01MB

 Claw wrench

*715589050700

 Retaining device

*715589003100

If the range group piston is damaged or the sealing ring is cut or deformed:



Replace the range group piston with a new one.

 The sealing ring and range group piston are assembled as one piece, so one should not attempt to replace only the sealing ring. The complete range group piston must be replaced.

31

Install the range group

AR26.31-B-3200DT

32

Apply seal to the contact surface of the range group housing with the idler housing

Loctite 5203 surface sealant

*BR00.45-Z-1129-02A

33

Install the range group in the transmission

AR26.31-B-3100DT

 Use an appropriate lifting equipment to lift the idler housing. Correctly align the multiplier group retaining plate with the pins in the idler housing. Use the mandrel assembly to align the housings.

  Housing screw

*BA26.10-B-1020-01MB

 Drift

*715589091500

34

Install the range group cylinder

AR26.18-B-3100DT

 Apply grease all over the range group shift piston sealing ring surface.

Klueber Polylub GLY 801 grease

*BR00.45-Z-1046-06A

35

Turn the transmission

 The clutch side should be upwards.

36

Determine the splitter group piston shim

AR26.35-B-0001-01DT

37

Install the splitter group piston

AR26.35-B-0100DT

38

Determine the splitter group cylinder shim

AR26.35-B-0001-02DT

39

Install the speed reducer group cylinder

AR26.18-B-1000DT

40

Determine the main shaft and countershaft adjustment shims

AR26.50-B-0410-03DT

41

Install the front-end flap

AR26.30-B-6510DT

42

Install a front-end flap with adjusting shims

AR26.30-B-0230DT

 Make sure that the adjustment shims are properly fitted to the bearing covers with the front-end flap.

 Replace the front-end flap sealing gasket with a new one.

 Correctly align the countershaft brake and the oil pump drive gear.

 Support

*055589163100

43

Install the clutch travel sensor on the clutch pneumatic central actuator

AR25.19-B-0100DT

44

Install the clutch pneumatic central actuator

AR25.20-B-0182DT

45

Place the transmission with the rear part up

46

Install the pulse wheel

AR26.19-B-0028DT

47

Install the rear oil retainer

AR26.40-B-3841DT

48

Install the coupling flange

AR26.50-B-2000DT

49

Install rear cover

AR26.30-B-3001DT

 Only for transmission without power takeoff.

50

Install the power take-off

NA MB 131-2c

AR26.45-B-0004DTB

NA MB 121-1b

AR26.45-B-0004DTA

51

Install the speed sensor

AR26.19-B-0006DT

52

Install the plastic bracket with compressed-air lines and electrical cables

  Harness bracket screw

*BA26.10-B-1021-01MB

53

Install the transmission actuator

AR26.21-B-0006DT

 Use a new gasket.

 Install the splitter group position sensor pin. Apply grease to the pin.

Klueber Polylub GLY 801 grease

*BR00.45-Z-1046-06A

54

Connect all electrical connectors to sensors


Take care not to damage the electrical connectors locks.
Otherwise the electrical connector will not be attached to the sensor correctly, which may cause transmission failures due to signal failure sent to the transmission actuator.

55

Mount all compressed-air line connections


Ensure correct installation of each compressed-air connection.
Otherwise the gearbox will not work properly.

  Compressed air connection

*BA26.10-B-1006-01MB

56

Fill transmission



AP26.00-B-2601MB

  Filling volume

*BF26.10-B-1002-01DT

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BA26.10-B-1006-01MB

Compressed air connection

Nm

17

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BA26.10-B-1009-01MB

Range group piston in the control rod

Nm

90

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BA26.10-B-1014-01MB

Fork guide-pin

Nm

120

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BA26.10-B-1020-01MB

Housing screw

Nm

80

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BA26.10-B-1021-01MB

Harness bracket screw

Nm

14

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BA26.10-B-1026-01MB

Reverse gear screw

Nm

58

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BA26.10-B-1032-01MB

Splitter group rod threaded plug

Nm

30

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BF26.10-B-1002-01DT

Filling volume

Transmission with retarder

Litro

9,4

Transmission without retarder

Litro

9,2

Oil class

Consultar documento BB00.40-B-0235-16A no site Mercedes-Benz / Guia de Lubrificantes

Repair materials

Number

Designation

Order number

BR00.45-Z-1046-06A

Klueber Polylub GLY 801 grease

A 001 989 84 51

BR00.45-Z-1129-02A

Loctite 5203 surface sealant

Henkel AG & Co. KGaA
http://www.loctite.de