G26.50-3215-09
1 Countershaft bearing cover
2 Tapered roller bearing outer race
3 Drive shaft bearing cap
4 Tapered roller bearing outer race
5 Guide bolts
6 Circlip
7 Front section of transmission housing
8 3rd/4th gear shift rail
9 3rd/4th gear shift fork
10 Oil pipe
20 Main shaft
21 Synchronizer ring
22 Input shaft
23 Shift mechanism
24 Bearing bolt for
3rd/4th gear shift fork
B3 Countershaft rpm sensor
S9 Neutral position switch
11 Countershaft
12 Tapered roller bearing outer race
13 Reverse gear
14 Range group
15 Reverse idler shaft
16 Bearing pin for 1st/2nd shift fork and reverse gear
17 Center section of transmission housing
18 Tapered roller bearing outer race
19 1st/2nd gear shift fork
| Assemble | ||
1 | Assemble countershaft (11) | ||
2 | Assemble (22) drive shaft | ||
3 | Assemble main shaft (20) | ||
4 | Install tapered roller bearing outer races (12, 18) in the transmission housing center part (17) | Use a suitable drift. The tapered roller bearing outer races (12, 18) must be installed in the center section of the transmission housing (17) from the inside, and inserted all the way against their seats. Lubricate tapered roller bearing outer races (12, 18) with multipurpose grease. | |
5 | Insert countershaft (11) into center section of transmission housing (17) | ||
6 | Install reverse idler gear (13) with bearing and bush | Check bearing and bush for wear and replace if necessary. The long collar of the reverse gear (13) must point towards the output. | |
7 | Attach lifting device to oil hole in main shaft (20) | ||
| Lifting device for removing and installing main shaft | ||
8 | Install shift fork for 1st/2nd gear (19) with sliding blocks and shift rail (8) on the main shaft (20) | Mount shift rail (8) on the main shaft (20). | |
9 | Insert main shaft (20) into center section of transmission housing (17) using lifting device | Push the countershaft (11) to one side. | |
10 | Install bearing pin for shift fork 1./2. and reverse gear (16) | Insert bearing pins with sealant. | |
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11 | Install synchronizer ring (21) | ||
12 | Install drive shaft (22) | Apply multipurpose grease to tapered roller bearings (pilot bearing). | |
13 | Align reverse gear (13) and insert reverse idler shaft (15) | | |
14 | Install oil pipe (10) | ||
15 | Install 3rd/4th gear shift fork (9) with sliding blocks and shift rail (8) | ||
16 | Install guide bolt in front section of transmission housing (7) | ||
| Guide bolt for installing range group | ||
17 | Fit front section of transmission housing (7) | Coat sealing surfaces with sealing compound. | |
18 | Screw in bolts around circumference of transmission housing | Remove guide studs (5) from the front section of the transmission housing (7) | |
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19 | Insert oil pipe (10) through bore and install locking ring (6) | ||
20 | Install bearing bolt for 3rd/4th gear shift fork (24) | Insert bearing pin for 3rd/4th gear shift fork (24) with sealing compound. | |
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21 | Install tapered roller bearing outer races (2, 4) as far as the stop | Use a suitable drift. Lubricate tapered roller bearing outer races (2, 4) with multipurpose grease. | |
22 | Drive dowel pins back roughly 20 mm from transmission housing center section (17) into the housing's front section (7) | ||
23 | Install countershaft bearing cover (1) and input shaft bearing cover (3) | ||
24 | Install clutch release lever | ||
25 | Install shift mechanism (23) | ||
26 | Install range group (14) | ||
27 | Install neutral position switch (S9) | | |
28 | Install countershaft rpm sensor (B3) | | |
29 | Attach electrical cable to connectors and brackets | | |
30 | Fill transmission with gear oil | To prevent damage to the transmission, always use gear oils contained in the Specifications for Operating Fluids: | |
| Gear oils | sheet 235.01 | |
| Gear oils | sheet 235.05 |
Sensors
Number | Designation | Transmission | ||
BA26.19-N-1003-01J | Rpm sensor (countershaft) to transmission housing | Nm | 40 | |
BA26.19-N-1006-01J | Neutral position switch to transmission housing | Nm | 60 | |
Housing
Number | Designation | Transmission 715.521/560 | |
BA26.40-N-1001-01N | Front section of transmission housing to center section of transmission housing | Nm | 70 |
BA26.40-N-1003-01N | Bearing bolt to shift fork (main shaft) | Nm | 120 |
BA26.40-N-1006-01N | Retaining panel of reverse shaft to transmission housing | Nm | 60 |
Repair materials
Number | Designation | Order number |
BR00.45-Z-1008-06A | Silicone-based grease | A 001 989 28 51 10 |
BR00.45-Z-1015-01A | Loctite 5203 sealant | A 002 989 71 20 10 |
BR00.45-Z-1133-02A | Loctite 243 | A 613 989 09 71 |
Referenced documents
- ar2520g0200b Remove and install clutch throwout lever
- ar2630g1010b Removing and installing input shaft and countershaft bearing covers
- ar2631g3102b Install range group
- ar2650g0426b Assembling transmission main shaft
- ar2650g4744ab Dismantle, assemble drive shaft.
- ar2650g4775ab Disassemble, assemble countershaft
- ar2660g0001ab Remove and install gearshift system
- bb0040p023501a Transmission oils (specification 235.1)
- bb0040p023505a Transmission oils SAE 80, 80 W/85 W (specification 235.5)
- wf5850n265005a Lifting device for removing and installing main shaft
- wf5850n310001a Guide bolt for installing range group