Assemble transmission

AR26.10-B-0010TKC

Assemble transmission

13.11.2018

Transmission

715.372/382/388 in model 958.4

with code GE3 (Mercedes PowerShift)

1

Intermediate shaft brake

11

Oil pipe

21

Main shaft (with gear shift unit)

2

Counter shaft bearing cap (front)

12

Intermediate shaft

22

Synchronizing cone with synchronizing ring and ring spring

3

Drive shaft cover

13

Counter shaft bearing cap (rear)

23

Shifting collar

4

Drive shaft bearing cap (front)

14

Reverse gear switch

24

Drive shaft

5

Clutch actuation lever

15

Multiplier group

25

Control unit

6

Range group's control bar

16

Reverse gear axle

26

Splitter group fork bolt

7

Front housing

17

Pin of the shift fork of the R/ 1st and of the 2nd/ 3rd gears

B3

Counter shaft rpm sensor

8

Lock

18

Central housing

B47

Oil temperature sensor

9

Splitter group coupling fork

19

Shim

10

Sliding shoes

20

Main shaft bearing cap (rear)

7

Front housing

30

Shift rail (R/ 1st gear)

31

Shift rail (2nd/ 3rd gear)

32

Coupling rail guide

33

Fixing device



Assemble

1

Assemble the counter-shaft (12)

.

AR26.50-B-4775TKC

2

Install drive shaft (24)

.

AR26.50-B-4744TKB

3

Assemble the secondary shaft (21)

.

AR26.50-B-0426TKC

4

Install the main shaft bearing cap (20) the countershaft bearing cap (13), with the shim (19) in the center housing (18)

 Utilize an appropriate mandrel.

 Apply multipurpose grease on the taper roller bearing caps (13 and 20).

VASELINE / DBL 6850.00

*BR00.45-Z-1098-06A

5

Mount the reverse gear gearwheel (14) with the bearing and bushing

 The long collar of the reverse gearwheel (14) has to point to the outlet side.

6

Assemble the counter shaft (21) with the main shaft (12) in the central carcass (18)

.

AR26.50-B-4000-02TKC

 Use the fastening device (33).

 Clamping device

*315589023100

 Retaining device

*715589013100

7

Assemble the fork pins (17)

 Apply chemical lock on the fork pins (17).

Araldite 2014 resin

*BR00.45-Z-1123-02A

 .Selection fork retaining pin in the gearbox

*BA26.35-B-1001-01C

8

Remove the fastening device (33) from the main shaft (21) and from the countershaft (12)

9

Place the synchronizer cone with synchronizer ring and annular spring (22) on the main shaft (21)

10

Install the shift sleeve (23)

 The long collar must point towards the motion output.

11

Install the drive shaft (24)

 Move the countershaft (12) to the side.

 Put multi-use grease on the drive shaft tapered roller bearing.

VASELINE / DBL 6850.00

*BR00.45-Z-1098-06A

12

Center the reverse gear gearwheel (14) and place the reverser gear shaft (16)

 .Reverse gear axle fastening plate

*BA26.40-B-1007-01L

13

Assemble the oil tube (11)

14

Assemble the splitter group coupling fork (9) with sliding bases (10)

15

Put the centering drift in the oil tube (11)

 Alignment punch

*715589031500

16

Put the guide pins in the front housing (7)



WF58.50-B-3100-01A

17

Fit the front case (7) in the center case (17)

 The coupling rails must slide on the front housing guide (7).

 Apply a sealant to the sealing faces.

Loctite 5203 surface sealant

*BR00.45-Z-1129-02A

18

Assemble the lock (8) on the oil tube (11) and remove the centering mandrel

19

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

 Pay attention to the different sizes of the bolts.

 .Front housing in the central housing

*BA26.40-B-1001-01L

20

Assemble the tapered roller bearing caps (2, 4)

 Utilize an appropriate mandrel.

 Put multi-use grease on the tapered roller bearing caps (2, 4).

VASELINE / DBL 6850.00

*BR00.45-Z-1098-06A

21

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

.

AR26.35-B-1000-03TA

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

22

Install the splitter group control bar

.

AR26.35-B-1000-04TA

 The coupling fork of the splitter group (9) must engage in the control rod's recess.

 Apply sealing compound to the closing screw.

 Put a quick drying binding product on the splitter group coupling fork pin (26).

Loctite 5203 surface sealant

*BR00.45-Z-1129-02A

Thread locking agent, Loctite 243 (10 ml)

*BR00.45-Z-1133-02A

 .Selection fork retaining pin in the gearbox

*BA26.35-B-1001-01C

23

Fasten the engagement rails (30, 31) to the guide (32) in the neutral position

 Use the fastening device (33).

 Retainer

*715589186300

24

Lift out the control rod of the split group (6) with the assembly tool, until the split group is engaged



Assembly tool for installing splitter group shift rod

WF58.50-B-2635-01A

25

Determine the shims for the input shaft (24) and countershaft (12)

.

AR26.50-B-0410-03TKB

.Pre-load of the primary shaft bearing

*BE26.50-B-1006-01G

.Intermediate shaft bearing adjustment clearance

*BE26.50-B-1007-01G

 .Primary and intermediate shaft bearings pre-tension

*BA26.50-B-1003-01C

 Torque screwdriver

*001589802100

 Clamping plates

*715589156300

26

Assemble the countershaft (1) brake with the determined shim

.

AR26.50-B-6000TKB

 The brake blades oil grooves must be aligned.

27

Assemble the drive shaft (3) cover with the determined shim

.

AR26.30-B-1020TKB

28

Position the gearbox in the horizontal position

29

Determine the compensation washer for the splitter group control piston

.

AR26.35-B-1000-01A

.Splitter group control piston adjustment dimension

*BE26.35-B-1001-01A

30

Lift out the control rod of the split group (6) with the assembly tool, until the split group is engaged



Assembly tool for installing splitter group shift rod

WF58.50-B-2635-01A

31

Assemble the double groove retainer and the control piston

 Lock the control piston with quick-drying adhesive.

 Smear synthetic grease on the double groove seal.

Quick-acting adhesive, Loctite 270

*BR00.45-Z-1008-02A

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 .Fastening of the splitter group control piston

*BA26.35-B-1002-01C

 Puller

*715589020700

32

Determine the compensation washer for the splitter group control cylinder

.

AR26.35-B-1000-02TA

.Splitter group control cylinder adjustment dimension

*BE26.35-B-1002-01A

 Internal extractor

*000589303300

 Counter stay

*000589343300

33

Remove the fastening device (33)

34

Assemble the operating unit (25)

.

AR26.60-B-0001TH

35

Install the oil temperature sensor (B47)

 .Transmission oil temperature sensor

*BA26.19-B-1004-01G

36

Install the countershaft rpm sensor (B3)

Vehicle with code (GE3) Mercedes PowerShift

.

AR26.19-B-0018TA

37

Assemble the range group (15)

.

AR26.31-B-3201TA

38

Assemble the range group (15)

.

AR26.31-B-3102TA

39

Install the compressed air tubes in the gear module, selection and engagement module, splitter group module, and power takeoff module

With compressed air connection system "VOSS 230".

.

AR42.10-B-0900TA

40

Install the electric cables in the connectors and supports

41

Install the clutch actuation lever

 .Gearbox fork

*BA25.20-B-1001-01L

Splitter box

Number

Designation

Transmission 715.372/382/388

BE26.35-B-1001-01A

Splitter group control piston adjustment dimension

mm

0,3...0,5

Splitter box

Number

Designation

Transmission 715.372/382/388

BE26.35-B-1002-01A

Splitter group control cylinder adjustment dimension

mm

0,4...0,5

Gear set

Number

Designation

Transmission 715.351/372/382/388

BE26.50-B-1006-01G

Pre-load of the primary shaft bearing

mm

0,00...-0,15

Gear set

Number

Designation

Transmission 715.351/372/382/388

BE26.50-B-1007-01G

Intermediate shaft bearing adjustment clearance

mm

-0,10...+0,05

 Clutch drive

Number

Designation

Type 934.241/251, 938.14 with engine 460.984 - 934.241/251, 958.4 with engine 457.9 - Type 958.2 with engine 906.9, 926.9

BA25.20-B-1001-01L

Gearbox fork

M12

Nm

90

M10

Nm

60

 Sensors/transmitters

Number

Designation

Transmission 715.351/372/382/388/531/535 in Type 958.2/4

BA26.19-B-1004-01G

Transmission oil temperature sensor

Nm

60

 Splitter box

Number

Designation

Transmission 715.372/382/388

BA26.35-B-1001-01C

Selection fork retaining pin in the gearbox

Nm

120

 Splitter box

Number

Designation

Transmission 715.372/382/388

BA26.35-B-1002-01C

Fastening of the splitter group control piston

Nm

95

 Housing

Number

Designation

Transmission 715.3

BA26.40-B-1001-01L

Front housing in the central housing

M12

Nm

70

 Housing

Number

Designation

Transmission 715.3

BA26.40-B-1007-01L

Reverse gear axle fastening plate

Nm

70

 Gears, shafts

Number

Designation

Transmission 715.351/372/382/388

BA26.50-B-1003-01C

Primary and intermediate shaft bearings pre-tension

Nm

15

Repair materials

Number

Designation

Order number

BR00.45-Z-1008-02A

Quick-acting adhesive, Loctite 270

A 002 989 93 71

BR00.45-Z-1027-06A

Synthetic grease 50 g

A 001 989 32 51 10

BR00.45-Z-1098-06A

VASELINE / DBL 6850.00

A 000 989 15 51

BR00.45-Z-1123-02A

Araldite 2014 resin

Huntsman Advanced Materials BVBA Everslaan 45
3078 Everberg, Belgium
Tel.: +41 61966 1599
Fax +41 61966 1589
www.huntsman.com
Order no. SF266243

BR00.45-Z-1129-02A

Loctite 5203 surface sealant

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

BR00.45-Z-1133-02A

Thread locking agent, Loctite 243 (10 ml)

A 613 989 09 71 09