Assemble transmission

AR26.10-W-0010NA

Assemble transmission

26.06.2020

Transmission

712.682 in model 967

with code G1D (Transmission G 90-6/6.70-0.73)

Transmission

715.066 in model 967

with code G1D (Transmission G 90-6/6.70-0.73)

1

Annular spring

13

5th and 6th gear gearshift arm

25

Rear section of transmission housing

2

Cover (countershaft)

14

Shift rails

26

Reverse gear shaft

3

Retaining ring

15

Main shaft

27

Locking screws

4

Retaining ring

16

Cap

28

Front section of transmission housing

5

Deep-groove ball bearing

17

End cover (only on vehicles without power take-off)

29

Reverse gear

6

Bearing pin

18

Spacer ring

30

Radial shaft sealing ring

7

Bearing pin

19

Pulse wheel

31

Guide tube (only with code G5H (manual gearshift))

8

Countershaft

20

Radial shaft sealing ring

B18

Travel and speed sensor (only for vehicles without transfer case)

9

Drive shaft

21

Output flange

B500

Output shaft rpm sensor (only for vehicles with transfer case)

10

Retaining ring

22

Pressure plate

B501

Main shaft rpm sensor

11

Tapered roller bearing (pilot bearing)

23

Screw

B502

Countershaft rpm sensor (only with code G5G (Mercedes PowerShift 3))

12

Shim

24

Supporting arm

B505

Transmission oil temperature sensor

8

Countershaft

15

Main shaft

36

Retaining spring

37

5th and 6th gear synchronizer unit

8

Countershaft

14

Shift rails

15

Main shaft

40

Support plate

41

Bracket

8

Countershaft

21

Output flange

25

Rear section of transmission housing

40

Support plate

42

Screw

43

Mounting irons

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW



Assemble

1

Assemble countershaft (8).

AR26.50-W-4775NA

2

Assemble main shaft (15).

AR26.50-W-0426NA

3

Assemble drive shaft (9).

AR26.50-W-4744NA

4

Install drive shaft (9) in transmission housing front section (28).

5

Install retaining ring (10) with zero clearance.

AR26.50-W-4743-01NA

 Assembly tool

*715589006300

6

Check play between deep-grooved ball bearing of drive shaft (9) and retaining ring (10) in transmission housing front section (28).

AR26.50-W-4743-03NA

Play of grooved ball bearing in front section of transmission housing

*BE26.50-N-1002-01NA

7

Assemble transmission housing rear section (25).

AR26.40-W-2476NA

8

Insert main shaft (15) and countershaft (8) into support plate (40).


Insert suitable spacer with 18 mm height (e.g. a nut) into mount of main shaft (15) on  support plate (40).
To ensure that the gears of the main shaft (15) and countershaft (8) mesh.

 Support plate

*715589316300

9

Fix reverse gear gearwheel in place at neutral position using suitable tool.

10

Attach shift rails (14) to main shaft (15).

 Fix shift rails (14) in place using cable ties and bracket.

 Bracket

*715589106300

11

Remove tool for fixing neutral position of reverse gear gearwheel.

12

Insert reverse idler gear (29) into transmission housing rear section (25).

 The long collar of the reverse idler gear (29) must point towards the drive.

13

Attach transmission housing rear section (25).

AR26.40-W-2475-08NA

 Secure reverse idler gear (29) when moving the rear section of the transmission housing (25).

14

Grease and install reverse idler gear axle (26).

 The reverse idler gear (29) and needle roller bearing must be fixed accurately into place.
Insert  of reverse idler gear axle (26), by hand, with the thread facing outwards, then drive in with a plastic mallet up to the end stop.

Long-life grease

*BR00.45-Z-1001-06A

15

Install cap (16).

 Clean sealing surfaces and coat with sealant.

 Cap and housing to transmission housing rear section

*BA26.40-N-1006-01G

Loctite 5203 sealant

*BR00.45-Z-1015-01A

16

Grease sealing lip of radial shaft sealing ring (20).

Synthetic grease 50 g

*BR00.45-Z-1027-06A

17

Install pulse wheel (19) and radial shaft sealing ring (20).

 Drift

*715589061500

18

Position transmission housing rear section (25) horizontally and remove support plate (40).

19

Install power output flange (21), pressure disk (22) and screw (23).

 Vehicle with code B3G (Permanent magnet retarder)
For a vehicle with this equipment, the bolt (23) only needs to be fastened finger-tight.

 Bolt, output flange

*BA26.50-N-1001-01NA

 Retainer wrench

*717589003100

20

Attach support plate (40) to power output flange (21) and place transmission housing rear section (25) onto attached support plate (40).

 Support plate

*715589316300

 Adapter set

*715589226300

21

Remove cable ties from shift rails (14).

22

Screw in locking screws (27) approx. 4 turns.

23

Check play of main shaft (15).

AR26.50-W-0420-10NA

Main shaft end float

*BE26.50-N-1005-01NA

24

Place shim (12) of determined thickness onto main shaft (15).

25

Grease and install tapered roller bearing (11).

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

26

Remove retaining springs (36) from 5th and 6th  gear synchronizer unit (37).

27

Install 5th and 6th gear gearshift swing arm (13) with sliding blocks.

 Observe direction of installation for sliding blocks. The rounded sides of the sliding blocks must face towards gearshift swing arm mounting.

28

Attach transmission housing front section (28) to transmission housing rear section (25) with aid of second person.

 Screw two centering screws/bolts into front section of transmission housing (28) for easier assembly.
Clean sealing surfaces and coat with sealant.
The shift rails (14) must slide into the front section of the transmission housing (28). While doing so, turn drive shaft (9) slightly using pliers.

 Transmission housing front section to transmission housing rear section

*BA26.40-N-1003-01G

Loctite 5203 sealant

*BR00.45-Z-1015-01A

 Pliers

*715589003700

29

Install bearing pins (6, 7) of 5th and 6th  gear gearshift swing arm (13).

 Align gearshift swing arm for 5th and 6th gear (13) through the opening in the front section of the transmission housing (28) with the bearing pins (6, 7).
To do so, insert bearing pins (6) with thread locking compound.

 Shift fork bearing pin at transmission housing

*BA26.60-N-1004-01NA

Thread locking agent, Loctite 243 (10 ml)

*BR00.45-Z-1133-02A

30

Support countershaft (8) at output side (arrow) relative to support plate (40).

 A metal piece 95 mm in length (e.g. a bolt (42) with at least Ø 14 mm) has to be used.

31

Install deep-groove ball bearing (5).

 Drive inner race of grooved ball bearing (5) up to end stop of countershaft (8).

 Drift

*387589051500

32

Insert retaining ring (4) with zero clearance and drive in with drift.

 If necessary, install a retaining ring (4) of a different thickness.

Play of grooved ball bearing on countershaft

*BE26.50-N-1006-01NA

 Drift

*387589051500

33

Remove support between countershaft (8) and support plate (40).

34

Drive outer race of deep-grooved ball bearing (5) into transmission housing front section (28) up to end stop.

 Drift

*387589051500

35

Insert retaining ring (3) with zero clearance and drive in with appropriate drift.

 If necessary install locking ring (3) of a different thickness.

Play of grooved ball bearing in front section of transmission housing

*BE26.50-N-1002-01NA

36

Install new cap (2).

 Drift punch

*314589031500

37

Install annular spring (1).

38

Grease new radial shaft sealing ring (30) on sealing lip and install.

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*715589001500

39

Install guide tube (31).

Only on vehicles with code G5H (Manual shift mechanism)

 Guide tube to transmission housing front section

*BA26.40-N-1005-01G

40.1

Install pneumatic central clutch release bearing.

Vehicles with code G5G (Mercedes PowerShift 3)

AR25.20-W-0182NA

40.2

Install release lever.

Vehicles with code G5H(shift mechanism, manual)

AR25.20-W-0200NA

41

Position transmission horizontally using suitable lifting gear and remove support plate (40).

42

Tighten locking screws (27).

 Lock bolts in transmission housing

*BA26.60-N-1005-01NA

43

Install gearshift system.

Vehicles with code G5H(shift mechanism, manual)

AR26.60-W-0001NA

Vehicles with code G5G (Mercedes PowerShift 3)

AR26.60-W-0001NAA

44

Install transmission positioner.

Only for vehicles with code G5G (Mercedes PowerShift 3)

AR26.21-W-0006NA

45

Install spacer ring (18).

Only on vehicles without power take-off

46

Clean sealing surface for end cover (17) or power take-off and coat with sealant.

Loctite 5203 sealant

*BR00.45-Z-1015-01A

47.1

Attach end cover (17).

Transmission without power take-off

 End cover to transmission housing rear section

*BA26.40-N-1004-01G

47.2

Install power take-off.

Transmission with power take-off

48

Install main shaft rpm sensor (B501).

 Main shaft rpm sensor to transmission housing

*BA26.19-N-1003-01NA

49.1

Install travel and speed sensor (B18).

Vehicles without transfer case

 Travel and speed rpm sensor to transmission

*BA26.19-N-1001-01NA

49.2

Install output shaft rpm sensor (B500).

Vehicles with transfer case

 Output shaft rpm sensor to transmission housing

*BA26.19-N-1009-01NA

50

Install transmission oil temperature sensor (B505).

 Transmission oil temperature sensor to transmission housing

*BA26.19-N-1004-01NA

51

Install countershaft rpm sensor (B502).

Only for vehicles with code G5G (Mercedes PowerShift 3)

 Replace O-ring.

 Countershaft rpm sensor to transmission housing

*BA26.19-N-1002-01NA

52

Attach lines to electrical connectors and to holders.

53

Attach support arm (24) on left of transmission.

If installed.

 Supporting arm to transmission

*BA26.10-N-1002-01NA

54

Remove power output flange (21) and attach to adapter of permanent magnet retarder.

Only on vehicles with code B3G (Permanent magnet retarder)

 Do not tighten the bolts yet.

55

Attach permanent magnet retarder with power output flange (21) to transmission.

Only on vehicles with code B3G (Permanent magnet retarder)

AR43.40-W-1007NA

Test and adjustment values for gear set

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BE26.50-N-1002-01NA

Play of grooved ball bearing in front section of transmission housing

mm

0,00...0,07

0,00...0,07

Test and adjustment values for gear set

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BE26.50-N-1005-01NA

Main shaft end float

mm

1,15 (0,1)

1,15 (0,1)

Test and adjustment values for gear set

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BE26.50-N-1006-01NA

Play of grooved ball bearing on countershaft

mm

0,00...0,07

0,00...0,07

 Manual transmission, complete

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BA26.10-N-1002-01NA

Supporting arm to transmission

Nm

165

190

 Sensors, transmitters

Number

Designation

Transmission 715.058/066

BA26.19-N-1001-01NA

Travel and speed rpm sensor to transmission

Nm

40

 Sensors, transmitters

Number

Designation

Transmission 715.058/066

BA26.19-N-1002-01NA

Countershaft rpm sensor to transmission housing

Nm

40

 Sensors, transmitters

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BA26.19-N-1003-01NA

Main shaft rpm sensor to transmission housing

Nm

40

40

 Sensors, transmitters

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BA26.19-N-1004-01NA

Transmission oil temperature sensor to transmission housing

Nm

40

40

 Sensors, transmitters

Number

Designation

Transmission 715.058/066

BA26.19-N-1009-01NA

Output shaft rpm sensor to transmission housing

Nm

40

 Housing

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BA26.40-N-1003-01G

Transmission housing front section to transmission housing rear section

Nm

60

60

 Housing

Number

Designation

Transmission 715.058/066

BA26.40-N-1004-01G

End cover to transmission housing rear section

Nm

60

 Housing

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BA26.40-N-1005-01G

Guide tube to transmission housing front section

Nm

25

25

 Housing

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BA26.40-N-1006-01G

Cap and housing to transmission housing rear section

Nm

60

60

 Gear set, shafts

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BA26.50-N-1001-01NA

Bolt, output flange

M12x1.5

Nm

­

­

M16x1.5

Nm

275

275

 Shift

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BA26.60-N-1004-01NA

Shift fork bearing pin at transmission housing

Nm

-

120

 Shift

Number

Designation

Transmission 712.671/682

Transmission 715.058/066

BA26.60-N-1005-01NA

Lock bolts in transmission housing

Nm

30

30

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

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