Assemble transmission

AR26.10-G-0010AE

Assemble transmission

04.03.2019

Transmission

715.537/538/539 in model 800

2

Splitter group cylinder

18

Shim

30

Drive shaft bearing cap

3

Splitter group shift rod

19

Tapered roller bearing outer race

31

Retaining ring

8

Sliding block

20

Main shaft

32

Reverse idler shaft

9

Oil pipe

21

Synchronizer cone with synchronizer ring and annular spring

35

Screw

10

Shift fork for splitter group

22

Sliding sleeve

36

Shift housing

11

Countershaft

23

Drive shaft

37

Front section of transmission housing

12

Tapered roller bearing outer race

25

Shift

38

Bearing pin

13

Shift unit

26

Bearing pin

B502

Countershaft rpm sensor

14

Center section of transmission housing

27

Tapered roller bearing outer race

B505

Transmission oil temperature sensor

15

Reverse gear

28

Tapered roller bearing outer race

S28

Neutral position switch

16

Reverse gear cap

29

Countershaft bearing cap

S29

Reverse gear switch

17

Range group

9

Oil pipe

11

Countershaft

13

Shift unit

14

Center section of transmission housing

20

Main shaft

50

Holding device

14

Center section of transmission housing

33

3rd/4th gear shift fork

38

Bearing pin

20

Main shaft

69

Oil restrictor

72

Transmission

73

Assembly device

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on compressed air connection systems

AH00.18-N-0001-01A



Assemble

1

Assemble countershaft (11).

AR26.50-G-4775AE

2

Assemble drive shaft (23).

AR26.50-G-4744AE

3

Assemble main shaft (20).

AR26.50-G-0428AE

4

Attach assembly device (73) to transmission housing center section (14) and move to vertical position.

AR26.10-W-0001-01HE

 Assembly device

*715589083100

5

Coat bearing surface of tapered roller bearing outer race (19) with lubricant.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

6

Slide spacer ring (18) onto tapered roller bearing outer race (19) and install using suitable drift from the inside up to the contact surface in the center section of the transmission housing (14).

7

Coat bearing surface of tapered roller bearing outer race (12) with lubricant.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

8

Install tapered roller bearing outer race (12) using suitable drift from inside up to contact surface in the center section of the transmission housing (14).

9

Install main shaft (20), countershaft (11) and shift unit (13) using holding device (50) into center section of transmission housing (14).

Transmission 715.537/538

AR26.50-W-4000-02HDA

Transmission 715.539

AR26.50-W-4000-02HDB

 Retaining device

*715589013100

 Clamping device

*315589023100

10

Install sliding sleeve (22).

 The long collar must point towards the output.

11

Coat tapered roller bearing (pilot bearing) on drive shaft (23) with lubricant and install drive shaft (23).

 Push the countershaft (11) to one side.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

12

Install both bearing pins (38).

 Note the different lengths of the various bearing pins; both bearing pins (38) are longer than the other bearing pins (26).
To do so, coat thread of bearing pins (38) with sealant and slightly lift up guide rails of shift unit (13).

Loctite 5203 sealant

*BR00.45-Z-1015-01A

13

Check the bearing and bushing of reverse idler gear (15) for wear and damage.

If wear or damage is visible,



Replace corresponding component.

14

Install reverse idler gear (15) with bearing and bushing.

 The long collar of the reverse idler gear (15) must point towards the output.

15

Center reverse idler gear (15) and insert reverse idler shaft (32).

 Bolt, reverse idler shaft retaining plate to transmission housing

*BA26.40-N-1007-01HA

16

Install radial shaft sealing ring and pilot bushing of shift rod for splitter box (3) into front section of transmission housing (37).

AR26.35-W-0002-01HA

 For this, coat radial shaft sealing ring with lubricant.

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

17

Clean sealing surfaces on front section of transmission housing (37) and center section of transmission housing (14) and coat with sealant.

Loctite 5203 sealant

*BR00.45-Z-1015-01A

18

Attach front section of transmission housing (37).

AR26.40-W-2470-08HD



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

 Splitter group shift rod lock to transmission housing

*BA26.35-N-1003-01HA

 Shift fork bearing pin at transmission housing

*BA26.35-N-1001-01HA

Loctite 5203 sealant

*BR00.45-Z-1015-01A

 Drift

*715589091500

 Puller

*715589083300

 Retaining device

*715589053100

 Alignment punch

*715589031500

19

Screw in bolts all round circumference of center section of transmission housing (14).

 Pay attention to different lengths of bolts.

 Bolt, transmission housing front section to transmission housing center section

*BA26.40-N-1001-01HA

20

Coat bearing surface of tapered roller bearing outer races (27, 28) with lubricant.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

21

Install tapered roller bearing outer races (27, 28) using suitable drift up to contact surface.

22

Pull out splitter box shift rod (3) using assembly tool.



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

23

Determine shims of drive shaft (23) and countershaft (11).

AR26.50-W-0410-03HD


Use a torque wrench with maximum indicator only.
Otherwise the tapered roller bearing outer races (27, 28) could be damaged.

Setting tolerance of bearings on countershaft

*BE26.50-N-1004-01HA

Drive shaft bearing pretension

*BE26.50-N-1003-01HA

 Preload of bushings on drive shaft and countershaft for determining shims

*BA26.50-N-1003-01HA

 Clamping plates

*715589156300

 Pliers

*715589013700

 Torque wrench

*000589672100

24

Install drive shaft bearing cap (30) and countershaft bearing cap (29) with determined shim.

25

Clean sealing surfaces on center section of transmission housing (14) and reverse idler gear cap (16) and coat with sealant.

Loctite 5203 sealant

*BR00.45-Z-1015-01A

26

Install reverse idler gear cap (16).

 Bolt, reverse idler gear cap to transmission housing center section

*BA26.40-N-1008-01HA

27

Remove assembly device (73) from transmission (72) and place transmission (72) into horizontal position.

AR26.10-W-0001-01HE

 Assembly device

*715589083100

28

Press in splitter box shift rod (3) using assembly tool.



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

29

Install shift piston of splitter box.

AR26.35-G-0001AE

30

Install splitter box cylinder (2).

AR26.18-G-1001AE

31

Install gearshift system (25).

AR26.60-G-0001AE

32

Install transmission oil temperature sensor (B505).

AR26.19-G-0017AE

33

Install countershaft rpm sensor (B502).

AR26.19-G-0018AE

34

Install reverse gear switch (S29).

AR26.19-G-0010AE

35

Install neutral position switch (S28).

AR26.19-G-0003AE

36

Install oil restrictor (69) on main shaft (20).

AR26.50-G-0004AD

37

Install range group (17).

AR26.31-G-3100AE

38

Install release lever.

 No work instructions have yet been prepared for this model.

39

Mount holder of compressed-air lines and electric lines onto transmission (72).

 Screw/bolt, bracket to transmission

*BA26.40-N-1009-01HA

40

Connect electrical connectors.

41

Mount compressed-air lines.

 See information from body manufacturer.

Test and adjustment values for gear set

Number

Designation

Transmission 715.537/538/539

BE26.50-N-1003-01HA

Drive shaft bearing pretension

mm

0,0...-0,15

Test and adjustment values for gear set

Number

Designation

Transmission 715.537/538/539

BE26.50-N-1004-01HA

Setting tolerance of bearings on countershaft

mm

-0,10...+0,05

 Splitter group

Number

Designation

Transmission 715.537/538/539

BA26.35-N-1001-01HA

Shift fork bearing pin at transmission housing

Nm

120

 Splitter group

Number

Designation

Transmission 715.537/538/539

BA26.35-N-1003-01HA

Splitter group shift rod lock to transmission housing

Nm

30

 Housing

Number

Designation

Transmission 715.537/538/539

BA26.40-N-1001-01HA

Bolt, transmission housing front section to transmission housing center section

Nm

80

 Housing

Number

Designation

Transmission 715.537/538/539

BA26.40-N-1007-01HA

Bolt, reverse idler shaft retaining plate to transmission housing

Nm

70

 Housing

Number

Designation

Transmission 715.537/538/539

BA26.40-N-1008-01HA

Bolt, reverse idler gear cap to transmission housing center section

Nm

50

 Housing

Number

Designation

Transmission 715.537/538/539

BA26.40-N-1009-01HA

Screw/bolt, bracket to transmission

M6

Nm

10

M8

Nm

25

M10

Nm

50

 Gear set, shafts

Number

Designation

Transmission 715.537/538/539

BA26.50-N-1003-01HA

Preload of bushings on drive shaft and countershaft for determining shims

Nm

10

Repair materials

Number

Designation

Order number

BR00.45-Z-1008-06A

Grease, silicone-based, 100 g

A 001 989 28 51

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1027-06A

Synthetic grease 50 g

A 001 989 32 51 10