Assemble transmission

AR26.10-W-0010KC

Assemble transmission

21.07.2017

Transmission

715.370/380

with code GE3 (Mercedes PowerShift)

Transmission

715.370/380

with code GE7 (Mercedes PowerShift 2)

Modification notes

26.09.2013

Special tool drift added.

Operation step 16, 19

715 589 09 15 00

17.09.2013

"Remove assembly device (73) from transmission (72) and place transmission (72) horizontally" added.

Operation step 28

AR26.10-W-0001-01HE

17.09.2013

"Install oil restrictor (69) at main shaft (21)" added.

Operation step 38

AR26.50-W-0004H

28.11.2013

Getriebegehäuse Vorderteil an Getriebegehäuse Mittelteil

GETRIEBE 715.370/380

BA26.40-N-1001-01KL

Shown on transmission 715.370 with code GE3 (Mercedes PowerShift)

1

Countershaft brake

11

Oil pipe

21

Main shaft (with shift unit)

2

Tapered roller bearing outer race

12

Countershaft

22

Synchronizer cone with synchronizer and annular spring

3

Drive shaft bearing cap

13

Tapered roller bearing outer race

23

Sliding sleeve

4

Tapered roller bearing outer race

14

Reverse gear

24

Drive shaft

5

Release lever

15

Range group

25

Shift

6

Splitter group shift rod

16

Reverse idler shaft

26

Bearing pin for splitter group shift fork

7

Front section of transmission housing

17

bearing bolt (reverse/1st gear shift fork and 2nd/3rd gear shift fork)

B3

Countershaft rpm sensor

8

Retaining ring

18

Center section of transmission housing

B47

Transmission oil temperature sensor

9

Shift fork for splitter group

19

Shim

B62

Splitter sensor (SSP)

10

Sliding blocks

20

Tapered roller bearing outer race

7

Front section of transmission housing

30

Shift rail (reverse/1st gear)

31

Shift rail (2nd/3rd gear)

32

Shift rail guide

33

Holding device

21

Main shaft

69

Oil restrictor

72

Transmission

73

Assembly device

Notes on compressed air connection systems

AH00.18-N-0001-01A



Assemble

1

Assemble countershaft (12)

AR26.50-W-4775KC

2

Assemble (24) drive shaft

AR26.50-W-4744KB

3

Assemble main shaft (21)

AR26.50-W-0426KC

4

Install tapered roller bearing outer races (13, 20) and spacer washer (19) in center section of transmission housing (18)

 Use a suitable drift. The tapered roller bearing outer races (13, 20) must be installed from inside in the center section of transmission housing (18).

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

5

Install reverse idler gear (14) with bearing and bush

 The long collar of the reverse gear (14) must point towards the output.

6

Use retainer (33) to insert main shaft (21) and countershaft (12) into center section of transmission housing (18)

AR26.50-W-4000-02KC

 Clamping device

*315589023100

 Retaining device

*715589013100

7

Install both bearing bolts (17)

 Insert bearing bolt (17) with quick-action adhesive.

 Shift fork bearing bolt to transmission housing

*BA26.35-N-1001-01KL

Thread locking agent, Loctite 243 (10 ml)

*BR00.45-Z-1133-02A

8

Remove holding device (33) from main shaft (21) and from countershaft (12)

9

Place synchronizer cone (with synchronizer ring and annular spring (22)) onto main shaft (21)

10

Install sliding sleeve (23)

 The long collar must point towards the output.

11

Install drive shaft (24)

 When doing so, push the countershaft (12) to one side.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

12

Center reverse idler gear (14) and insert reverse idler shaft (16)

 Retaining plate of reverse shaft to transmission housing

*BA26.40-N-1007-01KL

13

Install oil pipe (11)

14

Install splitter group shift fork (9) with sliding blocks (10)

15

Insert alignment punch into the oil pipe (11)

 Alignment punch

*715589031500

16

Screw drift into front section of transmission housing (7)

 Drift

*715589091500

17

Mount front section of transmission housing (7) onto center section of transmission housing (18)

 Coat sealing surfaces with sealant.
When fitting, the shift rails (30, 31) must slide into the guide in the transmission housing front section (7).

Loctite 5203 sealant

*BR00.45-Z-1015-01A

18

Install circlip (8) on oil pipe (11) and remove the centering drift from oil pipe (11)

19

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

 Pay attention to different lengths of bolts.

 Transmission housing front part to transmission housing center part

*BA26.40-N-1001-01KL

 Drift

*715589091500

20

Install tapered roller bearing outer races (2, 4) as far as the stop

 Use a suitable drift.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

21

Install radial shaft sealing ring and pilot bushing for splitter group shift rod (6)

AR26.35-W-1000-03A

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

22

Install splitter group shift rod (6)

AR26.35-W-1000-04A

 The splitter group shift fork (9) must engage in the recess in the splitter group shift rod (6).

 Splitter group shift rod lock to transmission housing

*BA26.40-N-1009-01KL

 Shift fork bearing bolt to transmission housing

*BA26.35-N-1001-01KL

Thread locking agent, Loctite 243 (10 ml)

*BR00.45-Z-1133-02A

Loctite 5203 sealant

*BR00.45-Z-1015-01A

23

Use holding device (33) to fix shift rails (30, 31) in the neutral position on the shift rail guide (32)

 Retainer

*715589186300

24

Pull out splitter group shift rod (6) using assembly tool until splitter position is engaged



Assembly tool for installing splitter group shift rod

WF58.50-N-2635-01A

25

Determine shims of input shaft (24) and countershaft (12)

AR26.50-W-0410-03KB

Drive shaft bearing pretension

*BE26.50-N-1006-01KL

Setting tolerance of bearings on countershaft

*BE26.50-N-1007-01KL

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

*BA26.50-N-1003-01KL

 Torque screwdriver

*001589802100

 Clamping plates

*715589156300

26

Install countershaft brake (1) with determined shim

AR26.50-W-6000KB

 The oil grooves of brake disks must be aligned.

27

Install bearing cap of input shaft (3) with the shim determined

AR26.30-W-1020KB

28

Remove assembly device (73) from transmission (72) and place transmission (72) horizontally

AR26.10-W-0001-01HE

 Assembly device

*715589083100

29

Determine shim for shift piston of splitter group

AR26.35-W-1000-01A

Adjustment dimension for gearshift piston of cascade box

*BE26.35-N-1001-01KL

30

Pull out splitter group shift rod (6) using assembly tool until splitter position is engaged



Assembly tool for installing splitter group shift rod

WF58.50-N-2635-01A

31

Install rubber sealing ring and shift piston

 Coat rubber sealing ring with synthetic grease.

 Shift piston to splitter group shift rod

*BA26.35-N-1002-01KL

Synthetic grease 50 g

*BR00.45-Z-1027-06A

Quick-acting adhesive, Loctite 270

*BR00.45-Z-1008-02A

 Puller

*715589020700

32

Determine shim for shift cylinder of splitter group

AR26.35-W-1000-02A

Adjustment dimension for splitter box shift cylinder

*BE26.35-N-1002-01KL

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Internal extractor

*000589303300

 Counter stay

*000589343300

33

Remove holding device (33)

34

Install shift mechanism (25)

AR26.60-W-0001H

35

Install transmission oil temperature sensor (B47)

 Transmission oil temperature sensor to transmission housing

*BA26.19-N-1004-01KL

36

Install countershaft speed sensor (B3)

Vehicles with code GE3 (Mercedes PowerShift)

AR26.19-W-0018A

Vehicles with code GE7 (Mercedes PowerShift 2)

AR26.19-W-0018KC

37

Install rpm sensor of main shaft (21)

Only on vehicles with code GE7 (Mercedes PowerShift 2).

AR26.19-W-0026KC

38

Install oil restrictor (69) on main shaft (21)

AR26.50-W-0004H

39

Assemble range group (15)

AR26.31-W-3201A

40

Install range group (15)

AR26.31-W-3102A

41

Attach compressed air line to gear module, gate module, shift cylinder of range group and power take-off

42

Mount electrical line onto connectors and holders

43

Install release lever (5)

 Release lever to transmissionRelease lever to transmission

*BA25.20-N-1001-01B

Inspection and adjustment data: splitter unit (splitter group)

Number

Designation

Transmission 715.370/380

BE26.35-N-1001-01KL

Adjustment dimension for gearshift piston of cascade box

mm

0,3...0,5

Inspection and adjustment data: splitter unit (splitter group)

Number

Designation

Transmission 715.370/380

BE26.35-N-1002-01KL

Adjustment dimension for splitter box shift cylinder

mm

0,4...0,5

Test and adjustment values for gear set

Number

Designation

Transmission 715.370/380

BE26.50-N-1006-01KL

Drive shaft bearing pretension

mm

0,0...–0,15

Test and adjustment values for gear set

Number

Designation

Transmission 715.370/380

BE26.50-N-1007-01KL

Setting tolerance of bearings on countershaft

mm

–0,10...+0,05

 Clutch operating system

Number

Designation

ENGINE 541.9, 542.9

BA25.20-N-1001-01B

Release lever to transmission

Nm

75

 Sensors, transmitters

Number

Designation

Transmission 715.370/380

BA26.19-N-1004-01KL

Transmission oil temperature sensor to transmission housing

Nm

60

 Splitter group

Number

Designation

Transmission 715.370/380

BA26.35-N-1001-01KL

Shift fork bearing bolt to transmission housing

Nm

120

 Splitter group

Number

Designation

Transmission 715.370/380

BA26.35-N-1002-01KL

Shift piston to splitter group shift rod

With special tool

Nm

90

Without special tool

Nm

95

 Housing

Number

Designation

Transmission 715.370/380

BA26.40-N-1001-01KL

Transmission housing front part to transmission housing center part

Nm

80

 Housing

Number

Designation

Transmission 715.370/380

BA26.40-N-1007-01KL

Retaining plate of reverse shaft to transmission housing

Nm

70

 Housing

Number

Designation

Transmission 715.370/380

BA26.40-N-1009-01KL

Splitter group shift rod lock to transmission housing

Nm

30

 Gear set, shafts

Number

Designation

Transmission 715.370/380

BA26.50-N-1003-01KL

Preload of bushings on drive shaft and countershaft for determining shims

Nm

15

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