Assemble transmission

AR26.10-W-0010HF

Assemble transmission

21.07.2017

Transmission

715.523

with code G2D (Transmission G 280-16/11.7-0.69)

Modification notes

27.11.2013

Bolt, transmission housing front section to transmission housing center section

Transmission 715.523

BA26.40-N-1001-01HA

Shown on transmission without transmission-independent power take-off (live PTO)

1

Compressed-air line

13

Shift unit

25

Shift

2

Splitter group shift cylinder

14

Center section of transmission housing

26

Bearing pin

3

Splitter group shift rod

15

Reverse gear

27

Tapered roller bearing outer race

4

Front section of transmission housing

16

Reverse gear cap

28

Tapered roller bearing outer race

5

Screw plug

17

Range group

29

Countershaft brake

6

Springs

18

Shim

30

Drive shaft bearing cap

7

Catch bolt

19

Tapered roller bearing outer race

31

Retaining ring

8

Sliding blocks

20

Main shaft

32

Reverse idler shaft

9

Oil pipe

21

Synchronizer cone with synchronizer ring and annular spring

34

Bearing pin

10

Shift fork for splitter group

22

Sliding sleeve

B501

Main shaft rpm sensor

11

Countershaft

23

Drive shaft

B502

Countershaft rpm sensor

12

Tapered roller bearing outer race

24

Electrical line

B505

Transmission oil temperature sensor

9

Oil pipe

11

Countershaft

13

Shift unit

14

Center section of transmission housing

20

Main shaft

50

Holding device

14

Center section of transmission housing

33

3rd/4th gear shift fork

34

Bearing pin

40

Holding device

41

Shaft

42

Scale

20

Main shaft

69

Oil restrictor

72

Transmission

73

Assembly device

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on compressed air connection systems

AH00.18-N-0001-01A



Assemble

1

Assemble countershaft (11)

AR26.50-W-4775HF

2

Assemble drive shaft (23)

AR26.50-W-4744HF

3

Assemble main shaft (20)

AR26.50-W-0426HF

4

Slide spacer washer (18) onto tapered roller bearing outer race (19) and install using suitable drift from the inside up to the contact surface in the center section of transmission housing (14)

 Coat the contact surface of the tapered roller bearing outer race (19) with lubricant.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

5

Drive tapered roller bearing outer race (12) into center section of transmission housing (14) from the inside as far as the contact surface using a suitable drift

 Coat the tread of the tapered roller bearing outer race (12) with lubricant.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

6

Install main shaft (20), countershaft (11) and shift unit (13) using holding device (50) into center section of transmission housing (14)

AR26.50-W-4000-02HF

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

 Clamping device

*315589023100

 Retaining device

*715589013100

7

Mount synchronizer cone with synchronizer ring and annular spring (21) onto main shaft (20)

 Lubricate synchronizer cone.

8

Install sliding sleeve (22)

 The long collar must point towards the output.

9

Coat tapered roller bearing (pilot bearing) on drive shaft (23) with lubricant and install drive shaft (23)

 Push the countershaft (11) to one side.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

10

Coat thread of both bearing pins (34) with sealant and screw in flush with guide rail

 To do this, lift guide rails of shift unit (13) slightly.

Loctite 5203 sealant

*BR00.45-Z-1015-01A

11

Install 3rd/4th gear shift forks (33) with sliding blocks and shift rails in sliding sleeve

12

Screw in both bearing pins (34) completely

 Shift fork bearing pin at transmission housing

*BA26.35-N-1001-01HA

13

Install reverse idler gear (15) with bearing and bush

 Check bearing and bush for wear and replace if necessary.
The long collar of the reverse idler gear (15) must point towards the output.

14

Align reverse idler gear (15) and insert reverse idler shaft (32)

 Bolt, reverse idler shaft retaining plate to transmission housing

*BA26.40-N-1007-01HA

15

Coat radial shaft sealing ring with lubricant and install with pilot bushing for splitter group shift rod (3) in transmission housing front section (4)

AR26.35-W-0002-01HA

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

16

Clean sealing surfaces on front section of transmission housing (4) and center section of transmission housing (14) and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

17

Install front section of transmission housing (4)



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

Transmission without transmission-independent power take-off (live PTO)

AR26.40-W-2470-08HB

Transmission with transmission-independent power take-off (live PTO)

AR26.40-W-2470-08HN

Loctite 5203 sealant

*BR00.45-Z-1015-01A

 Shift fork bearing pin at transmission housing

*BA26.35-N-1001-01HA

 Removal plate

*715589163300

 Alignment punch

*715589031500

 Retaining device

*715589053100

 Holding device

*715589073100

 Puller

*715589083300

 Drift

*715589091500

18

Screw in bolts around circumference of center section of transmission housing (14)

 Pay attention to different lengths of bolts.

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

*BA26.40-N-1001-01HA

19

Remove centering drift from oil pipe (9) and install retaining ring (31) onto oil pipe (9)

20

Detach support of oil pipe

21

Coat tread of tapered roller bearing outer races (27, 28) with lubricant

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

22

Using a suitable drift, install tapered roller bearing outer races (27, 28) up to contact surface

23

Install catch bolt (7) with springs (6)

24

Coat screw plug (5) with sealant and install

Loctite 5203 sealant

*BR00.45-Z-1015-01A

25

Pull out splitter group shift rod (3) using assembly tool



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

26

Use holding device (40) to fix shift rails of shift unit (13) into neutral position

 The shaft (41) of holding device (40) must be at zero degrees on the scale (42).

 Holding device

*715589246300

27

Determine shims of drive shaft (23) and countershaft (11)

Transmission without transmission-independent power take-off (live PTO)

AR26.50-W-0410-03HA

Transmission with transmission-independent power take-off (live PTO)

AR26.50-W-0410-03HN


Only use a torque wrench with slave pointer.
Otherwise the tapered roller bearing outer races (27, 28) may be damaged.

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

*BA26.50-N-1003-01HA

Drive shaft bearing pretension

*BE26.50-N-1003-01HA

Setting tolerance of bearings on countershaft

*BE26.50-N-1004-01HA

 Torque wrench

*000589672100

 Pliers

*715589013700

 Clamping plates

*715589156300

 Clamping plate

*715589296300

28

Install countershaft brake (29) with the determined shim

Transmission without transmission-independent power take-off (live PTO)

AR26.50-W-6000HA

Transmission with transmission-independent power take-off (live PTO)

AR26.50-W-6000HB

 The oil grooves of brake disks must be aligned.

29

Install bearing cap of drive shaft (30) with the determined shim

Transmission without transmission-independent power take-off (live PTO)

AR26.30-W-1020HA

Transmission with transmission-independent power take-off (live PTO)

AR26.30-W-1020HAA

30

Clean sealing surfaces on center section of transmission housing (14) and reverse idler gear cap (16) and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

31

Install reverse idler gear cap (16)

 Bolt, reverse idler gear cap to transmission housing center section

*BA26.40-N-1008-01HA

32

Remove assembly device (73) from transmission (72) and place transmission (72) in horizontal position

AR26.10-W-0001-01HE

 Assembly device

*715589083100

33

Press in splitter group shift rod (3) using assembly tool



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

34

Install shift piston of splitter group

AR26.35-W-0001HA

35

Install splitter group shift cylinder (2)

Transmission without transmission-independent power take-off (live PTO)

AR26.18-W-1001HA

Transmission with transmission-independent power take-off (live PTO)

AR26.18-W-1001HB

36

Install shift fork and power take-off sliding sleeve

Only for transmission with transmission-independent power take-off (live PTO).

AR26.45-W-0033N

37

Install power take-off

Only for transmission with transmission-independent power take-off (live PTO).

AR26.45-W-0039N

38

Install transmission oil temperature sensor (B505)

 Transmission oil temperature sensor to transmission housing

*BA26.19-N-1005-01HA

39

Install countershaft rpm sensor (B502)

 Bolt, countershaft rpm sensor to transmission housing

*BA26.19-N-1007-01HA

40

Install main shaft rpm sensor (B501)

 Bolt, main shaft rpm sensor to transmission housing

*BA26.19-N-1006-01HA

41

Install shift mechanism (25)

AR26.60-W-0001HA

42

Install oil restrictor (69) into main shaft (20)

AR26.50-W-0004H

43

Install range group (17)

AR26.31-W-3100HB

44

Install pneumatic central clutch release bearing

Only for vehicles with code G5G (Mercedes PowerShift 3).

AR25.20-W-0182H

45

Attach air lines and electrical lines with brackets to transmission (72)

 Bolt, bracket to transmission

*BA26.40-N-1009-01HA

46

Connect electrical connections at transmission control unit (TCM) (A5), transmission oil temperature sensor (B505), main shaft rpm sensor (B501) and countershaft rpm sensor (B502)

47

Attach electrical connections at live power take-off shift module (Y502) and live power take-off rpm sensor (B507)

Only for transmission with transmission-independent power take-off (live PTO).

48

Attach compressed air lines to transmission positioner (Y900) and range group shift cylinder

49

Attach air lines to power take-off

Only for transmission with transmission-driven power take-off.

50

Connect air lines to live power take-off shift module (Y502)

Only for transmission with transmission-independent power take-off (live PTO).

Test and adjustment values for gear set

Number

Designation

Transmission 715.523

BE26.50-N-1003-01HA

Drive shaft bearing pretension

mm

0,0...-0,15

Test and adjustment values for gear set

Number

Designation

Transmission 715.523

BE26.50-N-1004-01HA

Setting tolerance of bearings on countershaft

mm

-0,10...+0,05

 Sensors, transmitters

Number

Designation

Transmission 715.523

BA26.19-N-1005-01HA

Transmission oil temperature sensor to transmission housing

Nm

60

 Sensors, transmitters

Number

Designation

Transmission 715.523

BA26.19-N-1006-01HA

Bolt, main shaft rpm sensor to transmission housing

Nm

10

 Sensors, transmitters

Number

Designation

Transmission 715.523

BA26.19-N-1007-01HA

Bolt, countershaft rpm sensor to transmission housing

Nm

10

 Splitter group

Number

Designation

Transmission 715.523

BA26.35-N-1001-01HA

Shift fork bearing pin at transmission housing

Nm

120

 Housing

Number

Designation

Transmission 715.523

BA26.40-N-1001-01HA

Bolt, transmission housing front section to transmission housing center section

Nm

80

 Housing

Number

Designation

Transmission 715.523

BA26.40-N-1007-01HA

Bolt, reverse idler shaft retaining plate to transmission housing

Nm

70

 Housing

Number

Designation

Transmission 715.523

BA26.40-N-1008-01HA

Bolt, reverse idler gear cap to transmission housing center section

Nm

50

 Housing

Number

Designation

Transmission 715.523

BA26.40-N-1009-01HA

Bolt, bracket to transmission

M6

Nm

10

M8

Nm

25

M10

Nm

50

 Gear set, shafts

Number

Designation

Transmission 715.523

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

BR00.45-Z-1027-06A

Synthetic grease 50 g

A 001 989 32 51 10