Remove/install transmission housing

AR26.40-Y-2001A

Remove/install transmission housing

30.10.2019

Transmission

400.710 in model 400.204/207/212/216/231

Transmission

400.713 in model 831.247

Transmission housing rear section removal procedure

32

Special tool retaining spring 715 589 02 63 00

33

5th and 6th gearshift fork

34

Pilot bearing

35

Spacer

36

Special tool mounting plate 715 589 01 63 00

37

Special tool bracket-shift rail 715 589 10 63 00

24

Pulling hook 715 589 09 33 00

38

Companion flange nut

39

Special tool flange puller 090 589 76 33 00

40

Impact extractor - Big 602 589 00 33 00

41

Pulse wheel

40

Impact extractor - Big 602 589 00 33 00

43

Thread insert 904 589 00 63 00

44

Reverse idler gear

45

Special tool pulling device 715 589 11 33 00

46

Adaptor 1 715 589 11 34 00

47

Adaptor 2 715 589 12 34 00

48

Hydraulic cylinder 715 589 15 34 00

49

Hydraulic hose 652 589 00 33 23

50

Hand pump 652 589 00 33 21

36

Special tool mounting plate 715 589 01 63 00

168

Shift unit

Transmission housing rear section installation procedure

37

Special tool bracket - shift rail 715 589 10 63 00

44

Reverse idler gear

99

Special tool puller counter shaft 090 589 19 33 00

124

Special tool guide sleeve 715 589 02 14 00

13

Companion flange

14

Special tool retainer wrench - companion flange 717 589 00 31 00

41

Pulse wheel

125

Special tool drift - output end radial seal ring 715 589 06 15 00



Remove

1

Drain transmission oil.

2

Remove front section of the transmission housing from rear section.

AR26.40-Y-2470A

3

Clamp 5th and 6th gear synchronizer pack with special tool retaining spring (32).

 Clamping is necessary to avoid any dislocation during removal.

 Retaining spring

*715589026300

4

Remove 5th and 6th gearshift fork (33) from the gear assembly.

5

Remove pilot bearing (34) and spacer (35) from main shaft.

6

Remove the transmission from the special tool assembly stand and place it on workbench.

 Assembly stand

*090589029900

7

Install the special tool mounting plate (36) on the main shaft and counter shaft.

 Install with the shafts facing downwards.

 Mounting plate

*715589016300

8

Lock the shift rails using special tool bracket-shift rail (37).

 Bracket

*715589106300

9

Remove the companion flange nut (38).

10

Remove companion flange from the main shaft using special tool flange puller (39).

 Puller

*090589763300

11

Remove radial shaft sealing ring from transmission housing rear section.

 Use special tool pulling hook (24) and impact extractor - big (40) to remove radial shaft sealing ring.

 Pulling hook

*715589093300

 Impact extractor

*602589003300

12

Remove pulse wheel (41) from transmission housing rear section.

13

Remove reverse idler gear shaft from the rear transmission housing.

 Use special tool impact extractor - big (40) and thread insert (43) to remove reverse idler gear.

 Offset the reverse idler gear (44) using suitable screwdriver.

 Impact extractor

*602589003300

 Threaded insert

*904589006300

14

Remove transmission housing rear section from main shaft and counter shaft using combination of special tools.

 Use special tools pulling device (45), adapter 1 (46), adapter 2 (47), suitable distance piece, hydraulic cylinder (48), hydraulic hose (49), and hand pump (50) to remove transmission housing rear section.

 Pulling device

*715589113300

 Adapter

*715589113400

 Adapter

*715589123400

 Hydraulic cylinder

*715589153400

 Hydraulic hose (complete)

*652589003323

 Hand pump

*652589003321

15

Remove the idler gear (44) with needle roller bearing from transmission housing.

16

Detach the shift unit (168) from the main shaft.

17

Detach and remove main shaft from the mounting plate - transmission (36).

 Slide main shaft from its axis on the support plate to remove it.

 Mounting plate

*715589016300



Install

18

Install the reverse gear shift rail with fork, followed by 1st/2nd and 3rd/4th shift rail fork.

 Position the reverse gear wheel in neutral position.

19

Fix special tool bracket - shift rails (37) to the mounting plate - transmission.

 The special tool guides the shift rails during assembling.

 Bracket

*715589106300

20

Insert the 5th/6th shift rail into the bracket.

 Ensure the detent bolt seating on the shift rails are in position.

21

Insert reverse idler gear (44) in transmission housing rear section with needle roller bearing.

22

Install cylindrical roller bearing using special tool puller counter shaft (99).

 Puller

*090589193300

23

Fit special tool guide sleeve (124) over counter shaft.

 Tie the shift rails with main shaft using rope, so the shift rails will not dislocated the position during installation of transmission housing rear section.

 Sleeve

*715589021400

24

Offset reverse idler gear from its original axis.

25

Remove the clamping device.

 Assemble transmission housing rear section on main shaft and counter shaft before removing clamping device.

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

26

Heat the main shaft rear end bearing inner race and assemble the transmission housing.

 Heat up to 100°C by using heat air gun.

27

Pull main shaft bearing in transmission housing rear section on to main shaft.

 Ensure that shift rails slide into the guiding hole on the transmission housing rear section.

28

Install reverse idler gear shaft.



BB00.40-P-0267-01A

 Position the needle roller bearing and gear precisely. Grease the reverse gear shaft and insert 2/3rd by hand with thread pointing outwards and drive in as far as it stops using mallet.

29

Install pulse wheel (41) of speed sensor.

30

Install new oil seal using special tool drift-output end radial seal ring (125).

 Drift

*715589061500

31

Remove special tool mounting plate transmission.

 Place the transmission in horizontal position.

 Mounting plate

*715589016300

32

Install companion flange (13), washer and tighten bolt using special tool retainer wrench - companion flange (14).

 Transmission output flange

*BA26.10-Y-1020-01A

 Retainer wrench

*717589003100

33

Install special tool mounting plate - transmission to companion flange.

 Position the transmission vertically on the mounting plate.

 Mounting plate

*715589016300

34

Inspect main shaft end play.

AR26.50-Y-0003-01A

35

Assemble transmission front section to transmission unit.

AR26.40-Y-2470A

 G85 Transmission

Number

Designation

Transmission 400.710 in model 400.204/207/212/216/231
Transmission 400.713 in model 831.247

BA26.10-Y-1020-01A

Transmission output flange

Nm

275