Disassemble, assemble transmission

AR26.10-T-0001A

Disassemble, assemble transmission

16.6.10



Removing

1

Remove transmission

AR26.10-T-0020A

2

Drain transmission oil

Refer to maintenance manual.

3

Remove timing case

AR01.60-T-8200A

4

Fasten transmission on assembly stand

5

Unscrew starter lockout switch (36) and remove catch bolt (37)

 When doing so, detach the compressed air line from the bracket (42), unscrew the adapter (40) and remove the seal.

6

Unscrew backup lamp switch (38)

7

Remove shift mechanism

 When removed, the following components must also be removed:

- Gear sensor, gate sensor

- Gear shift cylinder, gate shift cylinder (28, 29)

- Shift mechanism with housing (30) and shift shaft bearing cap (31), shift hub bearing cap (32)

AR26.60-T-0001A

8

Remove rear section of transmission housing (1)



When removed, the following components must also be removed:

- Reverse gearwheel,

- Rear transmission cover (3),

countershaft end cover (2)

- Output flange (18),

- Speedometer sensor (22),

- Sensor of electropneumatic shifting aid (23)

and the axial play for the throughdrive countershaft and main shaft must be adjusted.

AR26.40-T-2475A

9

Remove left bearing pin (33) and right bearing pin (33) of 5th/6th gear shift fork on front section of transmission housing (13)

10

Remove shift forks (6) and shift rails (7)

AR26.60-T-0010A

11

Remove countershaft (8)

Attach a suitable holding device and lift countershaft out of front section of transmission housing using a crane.

12

Remove main shaft (5)

Attach hook and lift main shaft out of front section of transmission housing using a crane.



*620589016300

13

Remove countershaft bearing cap (9)

 To do so, turn the front section of the transmission housing so that the drive shaft is pointing upwards.

14

Remove shims (10) for countershaft (8) and seal (35) from countershaft bearing cap (9)

15

Drive outer race (12) of countershaft tapered roller bearing out of front section of transmission housing (13)



*312589151500

16

Remove input shaft bearing cap (14)

17

Remove shims (16) for input shaft (17) and seal (34) for input shaft bearing cap (14)

18

Remove drive shaft (17) with cylindrical roller bearing

 Turn the front section of the transmission housing on the assembly stand so that the drive shaft is horizontal. Drive out the drive shaft forwards using a plastic mallet.



Disassemble

19

Disassemble shift forks (6)

AR26.60-T-0010A

20

Disassemble main shaft (5)

AR26.50-T-0420A

21

Disassemble countershaft (8)

AR26.50-T-4775A

22

Disassemble drive shaft (17)

AR26.50-T-4744A

23

Disassemble rear transmission cover (3)

AR26.30-T-0315A

24

Disassemble reverse gear

AR26.50-T-4801A

25

Disassemble shift mechanism

With CODE (G61) Electropneumatic power shift (EPS)

AR26.60-T-6515A



Assemble

 Before assembly, clean all parts and check them for wear; fit new parts if necessary.

26

Assemble shift

With CODE (G61) Electropneumatic power shift (EPS)

AR26.60-T-6515A

27

Assemble reverse gear

AR26.50-T-4801A

28

Assemble rear transmission cover (3)

AR26.30-T-0315A

29

Assemble (17) drive shaft

AR26.50-T-4744A

30

Assemble countershaft (8)

AR26.50-T-4775A

31

Assemble main shaft (5)

AR26.50-T-0420A

32

Assemble shift forks (6)

AR26.60-T-0010A



Install

33

Determine shim (10) for countershaft bearing cap (9)

AR26.30-T-1000-02A

*BE26.50-N-1001-05A

34

Drive in drive shaft (17) using a plastic mallet

35

Determine shim (16) for input shaft bearing cap (14)

AR26.30-T-1000-01A

*BE26.50-N-1001-06A



*001589532100



*343589004000

36

Install countershaft bearing cap (9)



- Secure shims and gasket on bearing cap with grease. Install the thinnest shim in the bearing cap first.



*BA26.30-N-1004-01D

37

Drive outer race (12) of countershaft tapered roller bearing into front section of transmission housing (13)



- To do this, turn front section of transmission housing so that outer race of countershaft tapered roller bearing can be driven in from above using a drift and plastic mallet.

- The outer race of the tapered roller bearing must fit snugly at the bearing cap of the countershaft.



*312589151500

38

Install input shaft bearing cap (14)

Replace radial shaft seal.

- Install/remove radial shaft sealing ring on input shaft.

AR26.40-T-0335A

- Stick shims and gasket to bearing cap with grease.

- Grease radial shaft sealing ring.



*BA26.30-N-1005-01D

Long-life grease

*BR00.45-Z-1001-06A

39

Insert countershaft (8)

- Use suitable holding device and crane for lifting countershaft.

- When installing the countershaft, insert the inner race of the tapered roller bearing on the countershaft into the outer race of the tapered roller bearing in the front section of the housing.

- Ensure that the gearing of the countershaft and input shafts mesh.

40

Insert main shaft (5)

-  Attach hooks, use crane to lift main shaft.

- When installing the main shaft, insert the inner race of the cylindrical roller bearing on the main shaft into the race of the cylindrical roller bearing on the input shaft.

- Ensure that the splined shaft internal toothing of the synchronizer body of the direct gear engages in the splined shaft external gearing of the input shaft.

When inserting the main shaft, push countershaft to the side a little.



*620589016300

41

Install shift forks (6) and shift rails (7)

AR26.60-T-0010A

42

Screw left bearing pin (33) and right bearing pin (33) of 5th/6th gear shift fork into front section of transmission housing (13)

 Installation:

- Note different lengths of pins.

- Coat pin thread with sealant.



*BA26.60-N-1003-01E

*BR00.45-Z-1008-02A

43

Install rear section of transmission housing (1)

AR26.40-T-2475A

44

Install shift linkage.

AR26.60-T-0001A

45

Insert catch bolt (37) and screw in starter lockout switch (36)

When doing so, secure the compressed air line to the bracket (42) and attach the adapter (40) with a new seal (41).



*BA26.19-N-1006-01F

46

Screw in backup lamp switch (38)



*BA26.19-N-1005-01F

47

Attach timing case

AR01.60-T-8200A

48

Install transmission

AR26.10-T-0020A

49

Fill with transmission oil

Refer to maintenance manual.

Number

Designation

Trans-mission 714.669

BE26.50-N-1001-05A

Gap between outer race of countershaft tapered roller bearing and front face of constant countershaft gear

mm

28,750,1

Number

Designation

Trans-mission 714.669

BE26.50-N-1001-06A

End play of input shaft

mm

0,02-0,08

Number

Designation

Trans-mission 714.669 in model 671

BA26.19-N-1005-01F

Reverse lamp switch to transmission housing

M12

Nm

19

M18

Nm

30

M20

Nm

57

BA26.19-N-1006-01F

Starter interlock switch to transmission housing

M12

Nm

19

M20

Nm

57

Number

Designation

Trans-mission 714.669

BA26.30-N-1004-01D

Bolt, countershaft cap to front transmission housing

Nm

49

BA26.30-N-1005-01D

Bolt, front transmission cover to transmission housing

Nm

25

Number

Designation

Trans-mission 714.669

BA26.60-N-1003-01E

Shift fork bearing pin in transmission housing

Nm

200

Number

Designation

Order number

BR00.45-Z-1008-02A

Quick-acting adhesive, Loctite 270

A 002 989 93 71

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11