Modification notes |
11.09.2013 | "Screw drift into transmission housing front section (7)" added. | Operation step 17 | Dorn 715 589 09 15 00 |
11.09.2013 | "Remove drift from transmission housing front section (7) and screw in bolts around circumference of transmission housing front section (7)" added. | Operation step 20 | Dorn 715 589 09 15 00 |
16.09.2013 | "Install oil restrictor (69) at main shaft (22)" added. | Operation step 26 | AR26.50-W-0004H |
W26.10-1073-09
1 | Countershaft bearing cap | 11 | Countershaft | 21 | Shift unit | ||
2 | Tapered roller bearing outer race | 12 | Tapered roller bearing outer race | 22 | Main shaft | ||
3 | Drive shaft bearing cap | 14 | Range group | 23 | Synchronizer cone with synchronizer and annular spring | ||
4 | Tapered roller bearing outer race | 17 | Reverse idler shaft | 24 | Drive shaft | ||
5 | O-ring | 18 | Bearing bolt for shift unit | 25 | Shift | ||
6 | Retaining ring | 19 | Center section of transmission housing | B17 | Speed sensor | ||
7 | Front section of transmission housing | 20 | Tapered roller bearing outer race |
11 | Countershaft |
13 | Reverse gear |
15 | Centering drift |
16 | Oil pipe |
19 | Center section of transmission housing |
21 | Shift unit |
22 | Main shaft |
23 | Synchronizer cone with synchronizer and annular spring |
24 | Drive shaft |
26 | Holding device |
W26.10-1074-06
22 | Main shaft |
69 | Oil restrictor |
W26.50-1217-06
72 | Transmission |
73 | Assembly device |
W26.50-1216-12
| Assemble | ||
1 | Assemble countershaft (11) | ||
2 | Assemble (24) drive shaft | ||
3 | Assemble main shaft (22) and shift unit (21) | ||
4 | Install tapered roller bearing outer races (12, 20) in the transmission housing center part (19) | Use a suitable drift to install tapered roller bearing outer races (12, 20) from inside until they abut in the center section of transmission housing (19). | |
Grease, silicone-based, 100 g | |||
5 | Insert reverse gear (13) with bearing and bush in the transmission housing center part (19) | ||
6 | Screw in holding device (26) at the oil hole in the main shaft (22) | Retainer device | |
7 | Insert oil pipe (16) between the shift unit (21) and main shaft (22) | The groove for the retaining ring (6) must point upwards. | |
8 | Insert main shaft (22) together with shift unit (21) and oil pipe (16) into center section of transmission housing (19) using holding device (26) | The guides in the shift unit (21) and oil pipe (16) must be inserted into the corresponding holes in the transmission housing center part (19). | |
9 | Raise main shaft (22) approx. 15 mm and insert countershaft (11) in center section of transmission housing (19) | Lower the countershaft (11) and main shaft (22) simultaneously into the tapered roller bearing outer races (12, 20). | |
10 | Detach holding device (26) from main shaft (22) | ||
11 | Remove synchronizer cone with synchronizer and annular spring (23) | ||
12 | Insert drive shaft (24) | Grease the tapered roller bearing (pilot bearing). | |
Grease, silicone-based, 100 g | |||
13 | Remove cable ties (arrow) on both sides of the shift unit (21) | ||
14 | Center reverse gear (13), insert reverse shaft (17) and install locking device | Retaining panel of reverse shaft to transmission housing | |
15 | Insert alignment punch (15) in the oil pipe (16) | Alignment punch | |
16 | Clean sealing surfaces on front section of transmission housing (7) and on center section of transmission housing (19) and coat with sealing compound | Loctite 5203 sealant | |
17 | Screw drift into front section of transmission housing (7) | Drift | |
18 | Position transmission housing front section (7) on transmission housing center section (19) | Pay attention to the shift rods of the shift unit (21). | |
19 | Install retaining ring (6) and O-ring (5) on oil pipe (16) and remove centering drift | If necessary, lift up oil pipe (16) from below. | |
20 | 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 | |||
Drift | |||
21 | Coat thread of bearing bolts for shift unit (18) with quick-acting adhesive | Thread locking agent, Loctite 243 (10 ml) | |
22 | Install bearing bolts for shift unit (18) in the transmission housing center part (19) | The bores in the shift unit (21) must align with the bores in the transmission housing center part (19). | |
Bearing bolt to shift fork (main shaft) | |||
23 | Install tapered roller bearing outer races (2, 4) as far as the stop | Use a suitable drift. | |
Grease, silicone-based, 100 g | |||
24 | Install countershaft bearing cover (1) and input shaft bearing cover (3) | ||
25 | Remove assembly device (73) from transmission (72) and place transmission (72) horizontally | ||
Assembly device | |||
26 | Install oil restrictor (69) at main shaft (22) | ||
27 | Install range group (14) | ||
28 | Install shift mechanism (25) |
| |
Vehicles with code GS3 ("Hydraulic" gearshift) | |||
29 | Install reverse gear switch | Reverse gear switch to transmission housing | |
30 | Install rpm sensor of countershaft (11) | ||
31 | Install speed sensor (B17) | Speed sensor on output end of transmission cover | |
32 | Install clutch operating system | ||
33 | Attach electrical line and compressed air lines to connectors and to brackets |
715 589 08 31 00
Assembly device
715 589 03 15 00
Alignment punch
715 589 04 31 00
Retainer device
715 589 09 15 00
Drift
Referenced documents
- ar2610w000101he Attaching and detaching mounting device on transmission
- ar2619w0018a Remove/install countershaft speed sensor
- ar2630w1010c Remove/install drive shaft and countershaft bearing covers
- ar2631w3102b Install range group
- ar2650w0004h Remove/install oil restrictor on main shaft
- ar2650w0426e Assembling transmission main shaft
- ar2650w4744b Dismantle, assemble drive shaft.
- ar2650w4775h Disassemble, assemble countershaft
- ar2660w0001i Remove and install gearshift system
- ar2660w0001j Remove and install gearshift system