Assemble transmission · ar2610w0010nb · Mercedes-Benz WIS

AR26.10-W-0010NB

Assemble transmission

26.06.2020

Transmission	712.671 in model 967
	with code G1C (Transmission G 71-6/9.20-1.0)
Transmission	715.058 in model 967
	with code G1C (Transmission G 71-6/9.20-1.0)

W26.10-1189-09

1	Annular spring	12	Main shaft	23	Rear section of transmission housing
2	Cover (countershaft)	13	Cap	24	Guide tube (only with code G5H (manual gearshift))
3	Retaining ring	14	End cover (only on vehicles without power take-off)	25	Lock bolt
4	Retaining ring	15	Reverse gear shaft	26	Front section of transmission housing
5	Deep-groove ball bearing	16	Spacer ring	27	Radial shaft sealing ring
6	Countershaft	17	Pulse wheel	28	Reverse gear
7	Drive shaft	18	Radial shaft sealing ring	B18	Travel and speed sensor (only for vehicles without transfer case)
8	Retaining ring	19	Output flange	B500	Output shaft rpm sensor (only for vehicles with transfer case)
9	Cylindrical roller bearing	20	Pressure plate	B501	Main shaft rpm sensor
10	Shim	21	Screw	B502	Countershaft rpm sensor (only with code G5G (Mercedes PowerShift 3))
11	Shift rails	22	Supporting arm	B505	Transmission oil temperature sensor

6	Countershaft
9	Cylindrical roller bearing
10	Shim
11	Shift rails
12	Main shaft
23	Rear section of transmission housing
36	Retaining spring
37	5th and 6th gear synchronizer unit

W26.10-1197-06

6	Countershaft
11	Shift rails
12	Main shaft
40	Support plate
41	Bracket

W26.40-1114-03

6	Countershaft
19	Output flange
23	Rear section of transmission housing
40	Support plate
42	Screw
43	Mounting irons

W26.50-1269-11

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 (6).		AR26.50-W-4775NB
2	Assemble main shaft (12).		AR26.50-W-0426NB
3	Assemble drive shaft (7).		AR26.50-W-4744NA
4	Install drive shaft (7) in transmission housing front section (26).
5	Install retaining ring (8) with zero clearance.		AR26.50-W-4743-01NA
		 Assembly tool	*715589006300
6	Check play between deep-grooved ball bearing of drive shaft (7) and retaining ring (8) in transmission housing front section (26).		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 (23).		AR26.40-W-2476NA
8	Insert main shaft (12) and countershaft (6) into support plate (40).	 Insert suitable spacer with 18 mm height (e.g. a nut) into mount of main shaft (12) on mounting plate (40). To enable the gears of the main shaft (12) and countershaft (6) to mesh.
		 Support plate	*715589316300
9	Fix reverse gear gearwheel in place at neutral position using suitable tool.
10	Attach shift rails (11) to main shaft (12).	 Fix shift rails (11) into place using cable ties.
		 Bracket	*715589106300
11	Remove tool for fixing neutral position of reverse gear gearwheel.
12	Insert reverse idler gear (28) into transmission housing rear section (23).	 The long collar of the reverse idler gear (28) must face towards the powerplant.
13	Attach transmission housing rear section (23).		AR26.40-W-2475-08NA
		 Secure reverse idler gear (28) when moving the rear transmission housing section (23).
		 Hand pump	*652589003321
		 Hydraulic hose (complete)	*652589003323
		 Sleeve	*715589021400
		 Adapter	*715589113400
		 Pulling device	*715589123300
		 Adapter	*715589123400
		 Hydraulic cylinder	*715589153400
14	Grease and install reverse idler gear axle (15).	 The reverse idler gear (28) and needle roller bearing must be fixed accurately into place. Insert  of the reverse idler gear axle (15), facing outwards with thread, by hand, then drive in with plastic mallet up to end stop.
		Long-life grease	*BR00.45-Z-1001-06A
15	Install cap (13).	 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 (18).	Synthetic grease 50 g	*BR00.45-Z-1027-06A
17	Install pulse wheel (17) and radial shaft sealing ring (18).	 Drift	*715589061500
18	Position transmission housing rear section (23) horizontally and remove support plate (40).
19	Install power output flange (19), pressure disk (20) and screw (21).	 Vehicle with code B3G (Permanent magnet retarder) In a vehicle with this equipment, the bolt (21) only needs to be fitted finger-tight.
		 Bolt, output flange	*BA26.50-N-1001-01NA
		 Retainer wrench	*717589003100
20	Attach support plate (40) to power output flange (19) and place transmission housing rear section (23) onto attached support plate (40).	 Support plate	*715589316300
		 Adapter set	*715589226300
21	Remove cable ties from shift rails (11).
22	Screw in locking screws (25) approx.4 turns.
23	Check play of main shaft (12).		AR26.50-W-0420-10NA
		Main shaft end float	*BE26.50-N-1005-01NA
24	Place shim (10) of determined thickness onto main shaft (12).
25	Grease and install cylindrical roller bearing (9).	Grease, silicone-based, 100 g	*BR00.45-Z-1008-06A
26	Remove retaining springs (36) from 5th and 6th gear synchronizer unit (37).
27	Attach transmission housing front section (26) to transmission housing rear section (23) with aid of second person.	 Screw two centering bolts into front section of transmission housing (26) for easier assembly. Clean sealing surfaces and coat with sealant. The shift rails (11) must slide into the transmission housing front section (26). While doing so, turn drive shaft (7) 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
28	Support countershaft (6) 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.
		 Support plate	*715589316300
29	Install deep-groove ball bearing (5).	 Drive inner race of grooved ball bearing (5) up to end stop of countershaft (6).
		 Drift	*387589051500
30	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
31	Remove support between countershaft (6) and support plate (40).
32	Drive outer race of deep-grooved ball bearing (5) into transmission housing front section (26) up to end stop.	 Drift	*387589051500
33	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
34	Install new cap (2).	 Drift punch	*314589031500
35	Install annular spring (1).
36	Grease new radial shaft sealing ring (27) on sealing lip and install.	Synthetic grease 50 g	*BR00.45-Z-1027-06A
		 Drift	*715589001500
37	Install guide tube (24).	Only on vehicles with code G5H (Manual gearshift).
		 Guide tube to transmission housing front section	*BA26.40-N-1005-01G
38.1	Install pneumatic central clutch release bearing.	Vehicles with code G5G (Mercedes PowerShift 3)
			AR25.20-W-0182NA
38.2	Install release lever.	Vehicles with code G5H(shift mechanism, manual)
			AR25.20-W-0200NA
39	Position transmission horizontally using suitable lifting gear and remove support plate (40).
40	Tighten locking screws (25).	 Lock bolts in transmission housing	*BA26.60-N-1005-01NA
41	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
42	Install transmission positioner.	Only for vehicles with code G5G (Mercedes PowerShift 3)
			AR26.21-W-0006NA
43	Install spacer ring (16).	Only on transmissions without power take-off.
44	Clean sealing surface for end cover (14) or power take-off and coat with sealant.	Loctite 5203 sealant	*BR00.45-Z-1015-01A
45.1	Attach end cover (14).	Transmission without power take-off
		 End cover to transmission housing rear section	*BA26.40-N-1004-01G
45.2	Install power take-off.	Transmission with power take-off
46	Install main shaft rpm sensor (B501).	 Main shaft rpm sensor to transmission housing	*BA26.19-N-1003-01NA
47.1	Install travel and speed sensor (B18).	Vehicles without a transfer case
		 Travel and speed rpm sensor to transmission	*BA26.19-N-1001-01NA
47.2	Install output shaft rpm sensor (B500).	Vehicles with a transfer case
		 Output shaft rpm sensor to transmission housing	*BA26.19-N-1009-01NA
48	Install transmission oil temperature sensor (B505).	 Transmission oil temperature sensor to transmission housing	*BA26.19-N-1004-01NA
49	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
50	Attach lines to electrical connectors and to holders.	Only for vehicles with code G5G (Mercedes PowerShift 3)
51	Attach support arm (22) on left of transmission.	Only if fitted.
		 Supporting arm to transmission	*BA26.10-N-1002-01NA
52	Remove power output flange (19) and attach to adapter of permanent magnet retarder.	Only on vehicles with code B3G (Permanent magnet retarder)
		 Do not tighten the bolts yet.
53	Attach permanent magnet retarder with power output flange (19) to transmission.	Only on vehicles with code B3G (Permanent magnet retarder)

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 715.058/066
BA26.40-N-1005-01G	Guide tube to transmission housing front section	Nm	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-1005-01NA	Lock bolts in transmission housing	Nm	30	30

715 589 10 63 00

Bracket

715 589 00 15 00

Drift

715 589 12 34 00

Adapter

652 589 00 33 21

Hand pump

715 589 11 34 00

Adapter

715 589 12 33 00

Pulling device

652 589 00 33 23

Hydraulic hose (complete)

715 589 31 63 00

Support plate

715 589 02 14 00

Sleeve

387 589 05 15 00

Drift

715 589 22 63 00

Adapter set

314 589 03 15 00

Drift punch

715 589 15 34 00

Hydraulic cylinder

715 589 00 63 00

Assembly tool

715 589 00 37 00

Pliers

717 589 00 31 00

Retainer wrench

715 589 06 15 00

Drift

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

Referenced documents

ah0000n000101a Notes on self-locking nuts and bolts
ah0000p001501cw Note on calculation of tightening torque when using insertion or socket tools with various effective lengths
ah0000z001901a Notes on safety-relevant components
ar2520w0182na Remove/install pneumatic central clutch release bearing
ar2520w0200na Remove and install clutch throwout lever
ar2621w0006na Remove/install transmission positioner
ar2640w247508na Install transmission housing rear section
ar2640w2476na Disassemble/assemble rear section of transmission housing
ar2650w042010na Check main shaft end float
ar2650w0426nb Assembling transmission main shaft
ar2650w474301na Remove/install circlip
ar2650w474303na Checking play between grooved ball bearing and circlip in front section of transmission housing
ar2650w4744na Dismantle, assemble drive shaft.
ar2650w4775nb Disassemble, assemble countershaft
ar2660w0001na Remove and install gearshift system
ar2660w0001naa Remove and install gearshift system