Assemble transmission

AR26.10-W-0010C

Assemble transmission

21.07.2017

Transmission

715.500/507/510/513/517/520/527/540

Modification notes

02.10.2013

"Detach assembly device from transmission (72) and move transmission (72) to horizontal position" added.

Operation step 29

AR26.10-W-0001-01HE

02.10.2013

"Install oil restrictor (69) at main shaft (18)" added.

Operation step 35

AR26.50-W-0004H

1

Countershaft bearing cap

10

Oil pipe

18

Main shaft (with shift unit)

2

Tapered roller bearing outer race

11

Countershaft

19

Sliding sleeve

3

Drive shaft bearing cap

12

Tapered roller bearing outer race

20

Drive shaft

4

Tapered roller bearing outer race

13

Reverse gear

21

Shift

5

O-ring

14

Range group

22

Bearing pin for splitter group shift fork

6

Retaining ring

15

Bearing bolt for 1st/2nd, 3rd/4th shift fork and reverse gear

23

Reverse idler shaft

7

Front section of transmission housing

16

Center section of transmission housing

B3

Countershaft rpm sensor

8

Sliding block

17

Tapered roller bearing outer race

B47

Transmission oil temperature sensor

9

Shift fork for splitter group

17.1

Spacer washer (only with modified transmission housing center section (16))

S9

Neutral position switch

16

Center section of transmission housing

A

Distance (sealing surface to bearing seat)

18

Main shaft

69

Oil restrictor

72

Transmission

73

Assembly device



Assemble

1

Assemble countershaft (11)

AR26.50-W-4775B

2

Assemble drive shaft (20)

AR26.50-W-4744A

3

Assemble main shaft (18)

AR26.50-W-0426A

4

Measure distance (A) from sealing surface to bearing seat in transmission housing center section (16)

With distance (A) 327.5 mm:



Do not install spacer disk (17.1).

With distance (A) 328.5 mm:



Install spacer washer (17.1) under tapered roller bearing outer race (17).

5

Push spacer disk (17.1) onto tapered roller bearing outer race (17)

Only if the distance (A) in transmission housing center section (16) is 328.5 mm.

6

Drive tapered roller bearing outer race (12), tapered roller bearing outer race (17) and, if applicable, spacer washer (17.1) into transmission housing center section (16) from inside as far as stop using a suitable drift

 Grease the tapered roller bearing outer races (12, 17).

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

7

Install reverse idler gear (13) with bearing and bush

 The long collar of the reverse gear (13) must point towards the output.

8

Install the retainer at the oil hole in the main shaft (18)

 Retaining device

*715589013100

9

Install 3rd/4th gear shift fork, 1st/2nd gear shift fork with sliding blocks and shift rail at main shaft and attach reverse gear shift rail at retainer

 Observe correct sequence.

10

Attach countershaft (11) to the retainer

11

Use retainer to insert main shaft (18), countershaft (11) and shift forks into the center section of the transmission housing (16)

12

Install bearing pin for 1st/2nd, 3rd/4th and reverse gear shift forks (15)

 Insert the bearing pin for the 1st/2nd, 3rd/4th and reverse gear shift fork (15) with quick-action adhesive.

 Bearing bolt to shift fork (main shaft)

*BA26.40-N-1003-01D

Thread locking agent, Loctite 243 (10 ml)

*BR00.45-Z-1133-02A

13

Remove the retainer

14

Install sliding sleeve (19)

 The long collar must point towards the output.

15

Install drive shaft (20)

 Push the countershaft (11) to one side.
Grease the tapered roller bearing (pilot bearing).

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

16

Center reverse idler gear (13) and insert reverse idler shaft (23)

 Retaining panel of reverse shaft to transmission housing

*BA26.40-N-1006-01D

17

Install oil pipe (10)

18

Install splitter group shift fork (9) into sliding blocks (8)

19

Insert alignment punch into the oil pipe (10)

 Alignment punch

*715589031500

20

Screw drift into front section of transmission housing (7)

 Drift

*715589091500

21

Fit transmission housing front section (7) on transmission housing center section (16)

 Coat sealing surfaces with sealant.
When mounting, the shift rails must slide into the guide in the front section of transmission housing (7).

Loctite 5203 sealant

*BR00.45-Z-1015-01A

22

Install circlip (6) on oil pipe (10) and remove the centering drift from oil pipe (10)

23

Remove drift from front section of transmission housing (7) and screw in bolts around circumference of front section of transmission housing (7)

 Pay attention to different lengths of bolts.

 Transmission housing front section to transmission housing center section

*BA26.40-N-1001-01D

24

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

*BR00.45-Z-1008-06A

25

Install radial shaft sealing ring and pilot bushing for splitter group shift rod

AR26.35-W-1000-03A

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

26

Install splitter group shift rod

AR26.35-W-1000A

 The splitter group shift fork (9) must engage with the notch on the shift rod.

27

Install bearing pin for splitter group shift fork (22)

 Insert the bearing pin for the splitter group shift fork (22) with quick-action adhesive.

 Shift fork bearing bolt to transmission housing

*BA26.35-N-1001-01A

Thread locking agent, Loctite 243 (10 ml)

*BR00.45-Z-1133-02A

28

Install countershaft bearing cover (1) and input shaft bearing cover (3)

AR26.30-W-1010A

29

Detach assembly device from transmission (72) and move transmission (72) to horizontal position

AR26.10-W-0001-01HE

 Assembly device

*715589083100

30

Determine shim for shift piston of splitter group

AR26.35-W-1000-01A

Adjustment dimension for gearshift piston of cascade box

*BE26.35-N-1001-01A

31

Pull out shift rod using assembly tool



Assembly tool for installing splitter group shift rod

WF58.50-N-2635-01A

32

Install rubber sealing ring and shift piston

 Coat rubber sealing ring with synthetic grease.

 Shift piston to splitter group shift rod

*BA26.35-N-1002-01A

Synthetic grease 50 g

*BR00.45-Z-1027-06A

Quick-acting adhesive, Loctite 270

*BR00.45-Z-1008-02A

 Puller

*715589020700

33

Determine shim for shift cylinder of splitter group

AR26.35-W-1000-02A

Adjustment dimension for splitter box shift cylinder

*BE26.35-N-1002-01A

 Internal extractor

*000589303300

 Counter stay

*000589343300

34

Install gearshift system (21)

Vehicles with code GS1 ("Manual" gearshift).

AR26.60-W-0001E

Vehicles with code GS2 (Gear control)

AR26.60-W-0001B

Vehicles with code GS3 ("Hydraulic" gearshift) without code IY2 (Hydraulic fluid as per sheet 345.0).

AR26.60-W-0001D

Vehicles with code GS3 ("Hydraulic" gearshift) with code IY2 (Hydraulic fluid as per sheet 345.0).

AR26.60-W-0001K

Vehicles with code GS7 (Gear control II).

AR26.60-W-0001H

35

Install oil restrictor (69) at main shaft (18)

AR26.50-W-0004H

36

Assemble range group (14)

AR26.31-W-3201A

37

Install range group (14)

AR26.31-W-3102A

38

Install neutral position switch (S9)

Only on vehicles with code GS1 ("Manual" gearshift) or with code GS3 ("Hydraulic" gearshift)

 Neutral position switch to transmission housing

*BA26.19-N-1010-01A

39

Install transmission oil temperature sensor (B47)

 Transmission oil temperature sensor to transmission housing

*BA26.19-N-1006-01A

40

Install countershaft speed sensor (B3)

 Rpm sensor (countershaft) to transmission housing

*BA26.19-N-1007-01A

41

Mount electrical line onto connectors and holders

42

Install release lever

 Release lever at transmission, engine 906.9, 926.9Release lever to transmission

*BA25.20-N-1001-01N

 Release lever at transmission, engine 457.9, 541.9, 542.9Release lever to transmission

*BA25.20-N-1001-01B

Inspection and adjustment data: splitter unit (splitter group)

Number

Designation

TRANSMISSION 715.500 /507/510/513/517/ 520/527/540

BE26.35-N-1001-01A

Adjustment dimension for gearshift piston of cascade box

mm

0,3...0,5

Inspection and adjustment data: splitter unit (splitter group)

Number

Designation

TRANSMISSION 715.500 /507/510/513/517/ 520/527/540

BE26.35-N-1002-01A

Adjustment dimension for splitter box shift cylinder

mm

0,4...0,5

 Clutch operating system

Number

Designation

ENGINE 457.9

ENGINE 541.9, 542.9

BA25.20-N-1001-01B

Release lever to transmission

Nm

75

75

 Clutch operating system

Number

Designation

MODEL 374.5, 375.3, 950.5/6, 952.5/6, 953.6, 954.5, 957, 958.2 with ENGINE 902.9, 906.9, 926.9

BA25.20-N-1001-01N

Release lever to transmission

M10

Nm

50

M12

Nm

75

 Sensors, transmitters

Number

Designation

TRANSMISSION 715.500/507/510/513/517/520/527/540/561/567/568 with CODE GS1

TRANSMISSION 715.500/507/510/513/520/540 with CODE GS2

BA26.19-N-1006-01A

Transmission oil temperature sensor to transmission housing

Nm

60

60

 Sensors, transmitters

Number

Designation

TRANSMISSION 715.500/507/510/513/520/540/561 with CODE GS3

TRANSMISSION 715.500/507/510/513/520/540 with CODE GS7

BA26.19-N-1006-01A

Transmission oil temperature sensor to transmission housing

Nm

60

60

 Sensors, transmitters

Number

Designation

TRANSMISSION 715.500/507/510/513/520/540 with CODE BD9 and CODE GS7

BA26.19-N-1006-01A

Transmission oil temperature sensor to transmission housing

Nm

–

 Sensors, transmitters

Number

Designation

TRANSMISSION 715.500/507/510/513/517/520/527/540/561/567/568 with CODE GS1

TRANSMISSION 715.500/507/510/513/520/540 with CODE GS2

BA26.19-N-1007-01A

Rpm sensor (countershaft) to transmission housing

Nm

40

40

 Sensors, transmitters

Number

Designation

TRANSMISSION 715.500/507/510/513/520/540/561 with CODE GS3

TRANSMISSION 715.500/507/510/513/520/540 with CODE GS7

BA26.19-N-1007-01A

Rpm sensor (countershaft) to transmission housing

Nm

40

40

 Sensors, transmitters

Number

Designation

TRANSMISSION 715.500/507/510/513/520/540 with CODE BD9 and CODE GS7

BA26.19-N-1007-01A

Rpm sensor (countershaft) to transmission housing

Nm

–

 Sensors, transmitters

Number

Designation

TRANSMISSION 715.500/507/510/513/517/520/527/540/561/567/568 with CODE GS1

TRANSMISSION 715.500/507/510/513/520/540/561 with CODE GS3

BA26.19-N-1010-01A

Neutral position switch to transmission housing

Nm

60

60

 Splitter group

Number

Designation

TRANSMISSION 715.500/507/510/ 513/517/520/527/ 540

BA26.35-N-1001-01A

Shift fork bearing bolt to transmission housing

Nm

120

 Splitter group

Number

Designation

TRANSMISSION 715.500/507/510/ 513/517/520/527/ 540

BA26.35-N-1002-01A

Shift piston to splitter group shift rod

With special tool

Nm

90

Without special tool

Nm

95

 Housing

Number

Designation

Transmission 715.500/507/510/513/517/520/527/540

BA26.40-N-1001-01D

Transmission housing front section to transmission housing center section

Nm

80

 Housing

Number

Designation

Transmission 715.500/507/510/513/517/520/527/540

BA26.40-N-1003-01D

Bearing bolt to shift fork (main shaft)

Nm

120

 Housing

Number

Designation

Transmission 715.500/507/510/513/517/520/527/540

BA26.40-N-1006-01D

Retaining panel of reverse shaft to transmission housing

Nm

60

Repair materials

Number

Designation

Order number

BR00.45-Z-1008-02A

Quick-acting adhesive, Loctite 270

A 002 989 93 71

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

BR00.45-Z-1133-02A

Thread locking agent, Loctite 243 (10 ml)

A 613 989 09 71 09