Assemble transmission

AR26.10-W-0010HE

Assemble transmission

09.11.2017

Transmission

715.571

with code G1F (Transmission G 141-9/14.57-1.0)

Modification notes

06.02.2014

Install shift mechanism, added.

Operation step 29

1

Countershaft bearing cap

11

Range group

31

Threaded insert

2

Guide tube

12

Bearing pin (for shift unit)

33

Retaining ring

3

Drive shaft bearing cap

13

Shift module

34

Slide hammer puller

4

Tapered roller bearing outer race

14

Drive shaft

B18

Position and speed sensor (only for vehicles without 2-gear transfer case)

5

Tapered roller bearing outer race

15

Synchronizer cone with synchronizer ring and annular spring

B502

Countershaft rpm sensor

6

Countershaft

16

Main shaft

B505

Transmission oil temperature sensor

7

Front section of transmission housing

17

Shift unit

S28

Neutral position switch

8

Tapered roller bearing outer race

18

Tapered roller bearing outer race

S29

Reverse gear switch

9

Oil pipe

19

Reverse gear

10

Center section of transmission housing

30

Reverse idler shaft

6

Countershaft

9

Oil pipe

10

Center section of transmission housing

14

Drive shaft

16

Main shaft

17

Shift unit

A

Cable tie

B

Extension

C

Holding device

D

Centering drift

10

Center section of transmission housing

45

Holding device

Installation diagram showing bolts securing transmission housing center section to transmission housing front section

7

Front section of transmission housing

A

52 mm

B

62 mm

C

62 mm

Pfeile

Holes



Assemble

1

Assemble countershaft (6)

AR26.50-W-4775HE

2

Assemble drive shaft (14)

AR26.50-W-4744HE

3

Assemble main shaft (16)

4

Install holding device (45) for shift unit (17) on center section of transmission housing (10)

 Use 3 bolts M12x62.

 Holding fixture

*715589063100

5

Attach center section of transmission housing (10) to assembly device

AR26.10-W-0001-01HE

 The center section of the transmission housing (10) may only be mounted below the support arms.

 Assembly device

*715589083100

6

Install tapered roller bearing outer races (8, 18) in center section of transmission housing (10)

 Grease tapered roller bearing outer races (8, 18) with lubricant. Drive tapered roller bearing outer races (8, 18) into center section of transmission housing (10) from the inside as far as the stop using a suitable drift.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

7

Insert reverse gear (19) with bearing and bush into center section of transmission housing (10)

8

Install main shaft (16), countershaft (6), shift unit (17) and oil pipe (9) with holding device in center section of transmission housing (10)

AR26.50-W-4000-02HE

 Note installation of shift unit (17). The reverse gear (19) must be pushed to the side (arrow) in the process.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

 Retaining device

*715589013100

 Clamping device

*315589023100

9

Remove the retainer

10

Insert synchronizer cone with synchronizer ring and annular spring (15)

11

Insert drive shaft (14)

 Grease tapered roller bearing (pilot bearing) with lubricating grease.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

12

Center reverse gear (19) and install reverse idler shaft (30)

 Filling screw/inspection plug to transmission housing

*BA26.40-N-1006-01HA

13

Support oil pipe (9) at output end so that the groove for the retaining ring is at the same height as the tapered roller bearing

14

Remove cable tie from shift unit (17)

15

Insert centering drift (D) into oil pipe (9)

 Alignment punch

*715589031500

16

Clean sealing surfaces on front section of transmission housing (7) and center section of transmission housing (10) and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

17

Screw guide bolts into the front section of transmission housing (7)

 Observe length of guide pins. The guide pins cannot be inserted into 2 of the holes (arrows).
Use guide pin 03.

 Drift

*715589091500

18

Fit front section of transmission housing (7) on center section of transmission housing (10)

 Pay attention to the shift rods of the shift unit (17).

19

Unscrew guide pin from front section of transmission housing (7)

20

Bolt front section of transmission housing (7) onto center section of transmission housing (10)

 Pay attention to different lengths of bolts.

 Bolt, transmission housing front section to transmission housing center section

*BA26.40-N-1001-01HA

21

Remove centering drift (D) from oil pipe (9)

22

Install retaining ring (33) on oil pipe (9) and remove support

 If necessary, lift up oil pipe (9) from below.

23

Install both bearing pins (12)

 Coat bearing pins (12) with sealant. Screw in bolts on holding device (45) far enough until the bearing pins (12) line up in the guide rail.

 Bearing bolt to shift fork (main shaft)

*BA26.40-N-1003-01HA

Loctite 5203 sealant

*BR00.45-Z-1015-01A

24

Install tapered roller bearing outer races (4, 5) as far as the stop

 Grease tapered roller bearing outer races (4, 5) with lubricant.
Use a suitable drift.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

25

Determine shims of drive shaft (14) and countershaft (6)

AR26.50-W-0410-03HE


Only use a torque wrench with slave pointer.
Otherwise the tapered roller bearing outer races (8 and 18) may be damaged.

Drive shaft bearing pretension

*BE26.50-N-1003-01HA

Setting tolerance of bearings on countershaft

*BE26.50-N-1004-01HA

 Preload of bushings on drive shaft and countershaft for determining shims

*BA26.50-N-1003-01HA

 Torque wrench

*000589672100

 Pliers

*715589013700

 Pliers

*715589003700

 Clamping plates

*715589156300

26

Install countershaft bearing cap (1) and input shaft bearing cap (3) with the determined shims

27

Position transmission horizontally in support plate and remove assembly device

28

Detach holding device (45)

29

Install shift mechanism

AR26.60-W-0001HE

30

Install range group (11)

AR26.31-W-3100HE

31

Install reverse gear switch (S29)

 Reverse gear switch to transmission

*BA26.19-N-1011-01HA

32

Install neutral position switch (S28)

 Neutral position switch to transmission

*BA26.19-N-1012-01HA

33

Install countershaft rpm sensor (B502)

 Countershaft rpm sensor to transmission housing

*BA26.19-N-1008-01HA

34

Install transmission oil temperature sensor (B505)

 Transmission oil temperature sensor to transmission housing

*BA26.19-N-1005-01HA

35.1

Install travel and speed sensor (B18)

Vehicles without 2-gear transfer case

 Travel and speed rpm sensor to transmission

*BA26.19-N-1009-01HA

35.2

Install output shaft rpm sensor

Vehicles with 2-gear transfer case

 Output shaft rpm sensor to transmission housing

*BA26.19-N-1013-01HA

36

Install release lever

Model 964

AR25.20-W-0200H

Model 967

AR25.20-W-0200NA

37

Attach electrical lines and air lines to connections and brackets

Test and adjustment values for gear set

Number

Designation

Transmission 715.571

BE26.50-N-1003-01HA

Drive shaft bearing pretension

mm

0,0...-0,15

Test and adjustment values for gear set

Number

Designation

Transmission 715.571

BE26.50-N-1004-01HA

Setting tolerance of bearings on countershaft

mm

-0,10...+0,05

 Sensors, transmitters

Number

Designation

Transmission 715.571

BA26.19-N-1005-01HA

Transmission oil temperature sensor to transmission housing

Nm

60

 Sensors, transmitters

Number

Designation

Transmission 715.571

BA26.19-N-1008-01HA

Countershaft rpm sensor to transmission housing

Nm

40

 Sensors, transmitters

Number

Designation

Transmission 715.571

BA26.19-N-1009-01HA

Travel and speed rpm sensor to transmission

Nm

40

 Sensors, transmitters

Number

Designation

Transmission 715.571

BA26.19-N-1011-01HA

Reverse gear switch to transmission

Nm

60

 Sensors, transmitters

Number

Designation

Transmission 715.571

BA26.19-N-1012-01HA

Neutral position switch to transmission

Nm

60

 Sensors, transmitters

Number

Designation

Transmission 715.571

BA26.19-N-1013-01HA

Output shaft rpm sensor to transmission housing

Nm

40

 Housing

Number

Designation

Transmission 715.571

BA26.40-N-1001-01HA

Bolt, transmission housing front section to transmission housing center section

Nm

80

 Housing

Number

Designation

Transmission 715.571

BA26.40-N-1003-01HA

Bearing bolt to shift fork (main shaft)

Nm

120

 Housing

Number

Designation

Transmission 715.571

BA26.40-N-1006-01HA

Filling screw/inspection plug to transmission housing

Nm

60

 Gear set, shafts

Number

Designation

Transmission 715.571

BA26.50-N-1003-01HA

Preload of bushings on drive shaft and countershaft for determining shims

Nm

10

Repair materials

Number

Designation

Order number

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