Assemble transmission

AR26.10-G-0010D

Assemble transmission

20.12.2019

Transmission

714.190 in model 800

1

Main shaft

4

Bolts

6

Threaded hole

2

Bolts

5

Oil pipe bracket

7

Oil pipe

3

Countershaft

8

Transmission oil temperature sensor

10

Bearing pin

12

Rear section of transmission housing

9

Countershaft rpm sensor

11

Bolts

7

Oil pipe

12

Rear section of transmission housing

13

Drift

14

Dowel pins

12

Rear section of transmission housing

15

Reverse gear

A

Collar

7

Oil pipe

16

Fuse

17

Reverse gear shift fork

18

1st and 2nd gear shift fork

19

3rd gear and 2nd constant speed gear shift fork

20

Splitter box transmission shift fork

22

Shift rail

23

Shift rail

24

Shift rail

21

Sliding blocks

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 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

Notes on compressed air connection systems

AH00.18-N-0001-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW



Assemble

1

Assemble drive shaft.

AR26.50-G-4744C

2

Assemble countershaft (3).

AR26.50-G-4775C

3

Assemble main shaft (1).

AR26.50-G-0420C

4

Clean sealing surfaces on transmission housing rear section (12) and transmission housing front section.

5

Insert main shaft (1) and countershaft (3) together with drive shaft into transmission housing.

 Secure main shaft (1) and countershaft (3) to each other using a suitable tool.

6

Insert shift rails (22, 23, 24) into transmission housing.

 Observe installation position of shift rails (22, 23, 24).

7

Check sliding blocks (21).

If wear or damage is detected:



Replace respective sliding blocks (21).

8

Check reverse gear shift fork (17), 1st and 2nd gear shift fork (18), 3rd gear and 2nd constant speed gear shift fork (19), as well as splitter box transmission shift fork (20).

If wear or damage is detected:



Replace corresponding component.

9

Insert sliding blocks (21) into shift forks (17, 18, 19, 20).

 Ensure that the sliding blocks (21) are seated correctly. Coat sliding blocks (21) lightly with clean transmission oil.

10

Install reverse gear shift fork (17), 1st and 2nd gear shift fork (18), 3rd gear and 2nd constant speed gear shift fork (19), as well as splitter box transmission shift fork (20).

11

Insert retainer (16) of shift rail (22) (reverse gear).

12

Install oil pipe (7).

 Observe installation position of oil pipe (7).

13

Apply sealant to sealing surface of transmission housing front section.

Loctite 5203 sealant

*BR00.45-Z-1015-01A

14

Insert reverse idler gear (15) into transmission housing rear section (12).

 Observe installation position; the collar (A) points downward towards the clutch.

15

Insert drift (13) through hole in transmission housing rear section (12).



Assembly aid for removal/installation of transmission housing rear section

WF58.50-W-2640-04A

 The drift (13) is used for counterholding/centering the oil pipe (7).

16

Carefully lower transmission housing rear section (12) little by little onto transmission housing front section while counterholding oil pipe (7) at previously inserted drift (13).

 Make sure that the reverse idler gear (15) does not knock against the bearing of the countershaft.

17

Screw in screws (11).

 Screws (11) have different lengths, observe installation position.

 Screw/bolt, transmission housing rear section to transmission housing front section

*BA26.40-N-1003-01T

18

Align shift forks (17, 18, 19, 20) and screw in new bearing pins (10).

 Helper required.

 Shift fork bearing pin at transmission housing

*BA26.35-N-1002-02C

19

Install transmission oil temperature sensor (8) and countershaft rpm sensor (9).

 Screw, temperature sensor to transmission

*BA26.19-N-1001-01O

 Bolt, countershaft rpm sensor to transmission housing

*BA26.19-N-1002-01O

20

Pull drift (13) out of hole in transmission housing rear section (12).

21

Install reverse idler axle.

AR26.50-G-2002-01D

 Screw, reverse idler axle retaining plate

*BA26.50-N-1003-01R

 Extractor

*343589003301

 Alignment punch

*715589031500

 Threaded insert

*714589216300

22

Install oil pump.

AR26.55-G-3001D

23

Remove screw from threaded hole (6) and remove oil pipe bracket (5) from transmission.

24

Remove clamping plate from countershaft (3) and main shaft (1).

25

Install shift piston of splitter box.

AR26.35-G-1001D

26

Install countershaft brake (VGW-B).

AR26.50-G-6000A

27

Install drive shaft bearing cap.

AR26.30-G-1020D

28

Attach compressed-air line and electrical wiring harness with brackets to transmission.

29

Connect electrical connectors at transmission control unit (TCM), transmission oil temperature sensor (8), main shaft rpm sensor and countershaft rpm sensor (9).

30

Attach transmission to engine.

AR26.10-G-0037D

 Sensors, transmitters

Number

Designation

Transmission 714.190 in model 800

BA26.19-N-1001-01O

Screw, temperature sensor to transmission

Nm

60

 Sensors, transmitters

Number

Designation

Transmission 714.190 in model 800

BA26.19-N-1002-01O

Bolt, countershaft rpm sensor to transmission housing

M6

Nm

15

 Splitter group

Number

Designation

Transmission 714.190 in model 800

BA26.35-N-1002-02C

Shift fork bearing pin at transmission housing

Nm

120

 Housing

Number

Designation

Transmission 714.190 in model 800

BA26.40-N-1003-01T

Screw/bolt, transmission housing rear section to transmission housing front section

M20

Nm

80

 Gear set, shafts

Number

Designation

Transmission 714.190 in model 800

BA26.50-N-1003-01R

Screw, reverse idler axle retaining plate

Nm

60

Repair materials

Number

Designation

Order number

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10