Modification notes |
11.09.2013 | "Attach assembly device (73) to transmission housing center section (17) and move to upright position" added. | Step 5 | AR26.10-W-0001-01HE |
11.09.2013 | Special tool "drift (5)" added. | Operation steps 20, 22 | 715 589 09 15 00 |
11.09.2013 | "Remove assembly device (73) from transmission (72) and place transmission (72) horizontally" added. | Operation step 27 | |
11.09.2013 | "Install oil restrictor (69) at main shaft (20)" added. | Operation step 29 | AR26.50-W-0004H |
W26.50-1049-09
1 | Countershaft bearing cap | 10 | Oil pipe | 18.1 | Spacer washer (only on modified transmission housing center section (17)) | ||
2 | Tapered roller bearing outer race | 11 | Countershaft | 19 | 1st/2nd gear shift fork | ||
3 | Drive shaft bearing cap | 12 | Tapered roller bearing outer race | 20 | Main shaft | ||
4 | Tapered roller bearing outer race | 13 | Reverse gear | 21 | Synchronizer ring | ||
5 | Drift | 14 | Range group | 22 | Drive shaft | ||
6 | Retaining ring | 15 | Reverse idler shaft | 23 | Shift | ||
7 | Front section of transmission housing | 16 | Bearing pin (for 1st/2nd shift fork and reverse gear) | 24 | Bearing bolt for 3rd/4th gear shift fork | ||
8 | 3rd/4th gear shift rail | 17 | Center section of transmission housing | B3 | Countershaft rpm sensor | ||
9 | 3rd/4th gear shift fork | 18 | Tapered roller bearing outer race | S9 | Neutral position switch |
17 | Center section of transmission housing |
A | Distance (sealing surface to bearing seat) |
W26.40-1025-02
20 | Main shaft |
69 | Oil restrictor |
W26.50-1219-06
72 | Transmission housing |
73 | Transmission bracket |
W26.50-1216-12
| Assemble | ||
1 | Assemble countershaft (11) | ||
2 | Assemble drive shaft (22) | ||
3 | Assemble main shaft (20) | ||
4 | Attach assembly device (73) to transmission housing center section (17) and move to upright position | ||
Assembly device | |||
5 | Measure distance (A) from sealing surface to bearing seat in center section of transmission housing (17), added. | With distance (A) 327.5 mm: | |
| |||
Do not install spacer washer (18.1). | |||
With distance (A) 328.5 mm: | |||
| |||
Install the spacer washer (18.1) under the tapered roller bearing outer race (18). | |||
6 | Slide spacer washer (18.1) onto tapered roller bearing outer race (18) | Only if the distance (A) in transmission housing center section (17) is 328.5 mm. | |
7 | Drive tapered roller bearing outer race (12) and tapered roller bearing outer race (18), if necessary with spacer washer (18.1), into transmission housing center section (17) from inside as far as stop using a suitable drift | Grease tapered roller bearing outer races (12, 18). | |
Grease, silicone-based, 100 g | |||
8 | Insert countershaft (11) into center section of transmission housing (17) | ||
9 | Install reverse idler gear (13) with bearing and bush | The long collar of the reverse gear (13) must point towards the output. | |
10 | Attach lifting device to oil hole in main shaft (20) | ||
| Lifting device for removing and installing main shaft | ||
11 | Attach 1st/2nd gear shift fork (19) with sliding blocks and shift rail to main shaft (20) | Attach shift rails to the main shaft (20). | |
12 | Insert main shaft (20) into center section of transmission housing (17) using lifting device | Push the countershaft (11) to one side. | |
13 | Install bearing pin for shift fork 1./2. and reverse gear (16) | Insert the bearing pin (16) with quick-action adhesive. | |
Bearing bolt to shift fork (main shaft) | |||
Thread locking agent, Loctite 243 (10 ml) | |||
14 | Install synchronizer ring (21) | ||
15 | Install drive shaft (22) | Grease the tapered roller bearing (pilot bearing). | |
Grease, silicone-based, 100 g | |||
16 | Center reverse idler gear (13) and insert reverse idler shaft (15) | Retaining panel of reverse shaft to transmission housing | |
17 | Install oil pipe (10) | ||
18 | Install 3rd/4th gear shift fork (9) with sliding blocks and 3rd/4th gear shift rail (8) | ||
19 | Insert alignment punch into the oil pipe (10) | Alignment punch | |
20 | Install drift (5) in transmission housing front section (7) | Drift | |
21 | Mount front section of transmission housing (7) onto center section of transmission housing (17) | Coat sealing surfaces with sealant. | |
Loctite 5203 sealant | |||
22 | Remove drift (5) from transmission housing front section (7) and screw in bolts around circumference of transmission housing front section (7) | Pay attention to different lengths of bolts. | |
Transmission housing front section to transmission housing center section | |||
Drift | |||
23 | Install circlip (6) on oil pipe (10) and remove the centering drift from oil pipe (10) | ||
24 | Install bearing bolt for 3rd/4th gear shift fork (24) | Insert the bearing pin for the 3rd/4th gear shift fork (24) with quick-action adhesive. | |
Bearing bolt to shift fork (main shaft) | |||
Thread locking agent, Loctite 243 (10 ml) | |||
25 | Using a suitable drift, install tapered roller bearing outer races (2, 4) until they abut | Grease the tapered roller bearing outer races (2, 4). | |
Grease, silicone-based, 100 g | |||
26 | Install countershaft bearing cover (1) and input shaft bearing cover (3) | ||
27 | Remove assembly device (73) from transmission (72) and place transmission (72) horizontally | ||
28 | Install gearshift system (23) |
| |
Vehicles with code GS3 ("Hydraulic" gearshift) with code IY2 (Hydraulic fluid as per sheet 345.0) | |||
29 | Install oil restrictor (69) into main shaft (20) | ||
30 | Install range group (14) | ||
The oil pipe (70) and the retaining ring (71) are no longer required because of a technical modification. | |||
31 | Install neutral position switch (S9) | Neutral position switch to transmission housing | |
32 | Install countershaft speed sensor (B3) | Rpm sensor (countershaft) to transmission housing | |
33 | Attach electrical line to connectors and to brackets | ||
34 | Install release lever | Release lever at transmission, engine 906.9, 926.9Release lever to transmission | |
Release lever at transmission, engine 457.9Release lever to transmission |
715 589 08 31 00
Assembly device
715 589 03 15 00
Alignment punch
715 589 09 15 00
Drift
Referenced documents
- ar2610w000101he Attaching and detaching mounting device on transmission
- ar2630w1010a Remove/install drive shaft and countershaft bearing covers
- ar2631w3102a Install range group
- ar2650w0004h Remove/install oil restrictor on main shaft
- ar2650w0426c Assembling transmission main shaft
- ar2650w4744e Dismantle, assemble drive shaft.
- ar2650w4775f Disassemble, assemble countershaft
- ar2660w0001g Remove and install gearshift system
- ar2660w0001k Remove and install gearshift system
- wf5850n265005a Lifting device for removing and installing main shaft