Modification notes |
26.09.2013 | Special tool drift added. | Operation step 19 | 715 589 09 15 00 |
17.09.2013 | "Remove assembly device (73) from transmission (72) and place transmission (72) horizontally" added. | Step 32 | AR26.10-W-0001-01HE |
17.09.2013 | Install oil restrictor (69) onto main shaft (19), added. | Operation step 40 | AR26.50-W-0004H |
28.11.2013 | Getriebegehäuse Vorderteil an Getriebegehäuse Mittelteil | GETRIEBE 715.515/525 | BA26.40-N-1001-01KL |
W26.50-1110-09
Shown on transmission with countershaft brake with 3 internal plates |
1 | Countershaft bearing cap (only on countershaft brake with 3 internal plates) | 13 | Reverse gear | 24 | Reverse idler shaft | ||
2 | Tapered roller bearing outer race | 14 | Range group | 25 | Countershaft brake compressed air line | ||
3 | Drive shaft bearing cap | 15 | Bearing pin (for 1st/2nd shift fork and reverse gear) | 26 | Shift fork (3rd/4th gear) | ||
4 | Tapered roller bearing outer race | 16 | Bearing bolt (for 3rd/4th gear shift fork) | 27 | Shift fork (1st/2nd gear) | ||
5 | Countershaft brake | 17 | Center section of transmission housing | 28 | Shift rail (reverse gear) | ||
6 | Retaining ring | 18 | Tapered roller bearing outer race | 29 | Shift rail (1st/2nd gear) | ||
7 | Front section of transmission housing | 18.1 | Spacer washer (only on modified transmission housing center part) | 30 | Shift rail (3rd/4th gear) | ||
8 | Sliding block | 19 | Main shaft (with shift unit) | 31 | Holding device | ||
9 | Shift fork for splitter group | 20 | Sliding sleeve | B3 | Countershaft rpm sensor | ||
10 | Oil pipe | 21 | Drive shaft | B47 | Transmission oil temperature sensor | ||
11 | Countershaft | 22 | Shift | ||||
12 | Tapered roller bearing outer race | 23 | Bearing pin for splitter group shift fork |
7 | Front section of transmission housing |
28 | Shift rail (reverse gear) |
29 | Shift rail (1st/2nd gear) |
30 | Shift rail (3rd/4th gear) |
32 | Shift rail guide |
33 | Holding device |
W26.60-1225-02
17 | Center section of transmission housing |
A | Distance (sealing surface to bearing seat) |
W26.40-1025-02
19 | Main shaft |
69 | Oil restrictor |
W26.50-1218-06
72 | Transmission |
73 | Assembly device |
W26.50-1216-12
Notes on compressed air connection systems | |||
| Assemble | ||
1 | Assemble countershaft (11) | ||
2 | Assemble drive shaft (21) | ||
3 | Assemble main shaft (19) | ||
4 | Measure distance (A) from sealing surface to bearing seat in center section of transmission housing (17), added. | With distance (A) 327.5 mm: | |
| |||
Do not install spacer washer (18.1). | |||
With distance (A) 328.5 mm: | |||
| |||
Install the spacer washer (18.1) under the tapered roller bearing outer race (18). | |||
5 | Using a suitable drift, install tapered roller bearing outer race (18) and tapered roller bearing outer race (12), if necessary with the spacer washer (18.1) in the center section of transmission housing (17) from inside until they abut | Grease tapered roller bearing outer races (12, 18). | |
Grease, silicone-based, 100 g | |||
6 | Install reverse idler gear (13) with bearing and bush | The long collar of the reverse gear (13) must point towards the output. | |
7 | Install retainer (31) on oil passage in main shaft (19) | Retaining device | |
8 | Install shift forks (26, 27) with sliding blocks on main shaft (19) and attach shift rails (28, 29, 30) at retainer (31) | Observe correct sequence. | |
9 | Attach countershaft (11) to the retainer (31) | ||
10 | Insert main shaft (19), countershaft (11) and shift forks (9, 26, 27) into center section of transmission housing (17) | ||
11 | Install bearing pins (15, 16) | Insert bearing bolts (15, 16) with quick-action adhesive. | |
Bearing pin to shift fork (main shaft) | |||
Thread locking agent, Loctite 243 (10 ml) | |||
12 | Detach holding device (31) | ||
13 | Install sliding sleeve (20) with the long collar pointing towards the output | ||
14 | Install drive shaft (21) | Push the countershaft (11) to one side. | |
Grease, silicone-based, 100 g | |||
15 | Align reverse idler gear (13) and insert reverse idler shaft (24) | Retaining plate of reverse shaft to transmission housing | |
16 | Install oil pipe (10) | ||
17 | Install splitter group shift fork (9) into sliding blocks (8) | ||
18 | Insert alignment punch into the oil pipe (10) | Alignment punch | |
19 | Screw drift into front section of transmission housing (7) | Drift | |
20 | Mount front section of transmission housing (7) onto center section of transmission housing (17) | Coat sealing surfaces with sealant. | |
Loctite 5203 sealant | |||
21 | Install circlip (6) on oil pipe (10) and remove the centering drift from oil pipe (10) | ||
22 | Remove drift from front section of transmission housing (7) and screw in bolts around circumference of front section of transmission housing (7) | Pay attention to different lengths of bolts. | |
Transmission housing front part to transmission housing center part | |||
Drift | |||
23 | Using a suitable drift, install tapered roller bearing outer races (2, 4) until they abut | Grease the tapered roller bearing outer races (2, 4). | |
Grease, silicone-based, 100 g | |||
24 | Install radial shaft sealing ring and pilot bushing for splitter group shift rod | ||
Synthetic grease 50 g | |||
Drift | |||
25 | Install splitter group shift rod | ||
The splitter group shift fork (9) must engage with the notch on the shift rod. | |||
26 | Insert bearing pin for splitter group shift fork (23) using fast-action adhesive | Shift fork bearing bolt to transmission housing | |
Thread locking agent, Loctite 243 (10 ml) | |||
27 | Use the holding device (33) to fix shift rails (28, 29, 30) in the neutral position on shift rail guide (32) | Retainer | |
28 | Determine shims of drive shaft (21) and countershaft (11) |
| |
Countershaft brake with 3 internal plates. | |||
| Assembly tool for installing splitter group shift rod | ||
Preload of bushings on drive shaft and countershaft for determining shims | |||
Drive shaft bearing pretension | |||
Setting tolerance of bearings on countershaft | |||
Torque screwdriver | |||
Clamping plates | |||
29 | Install bearing cap of input shaft (3) with the shim determined | ||
30 | Install countershaft bearing cap (1) with the shim determined | On countershaft brake with 3 internal plates. | |
Countershaft bearing cap to housing | |||
31.1 | Install countershaft brake (5) | On countershaft brake with 3 internal plates. | |
The oil grooves of the brake disks must be in a line. | |||
31.2 | Install countershaft brake (5) with the shim determined | On countershaft brake with 5 internal plates | |
The oil grooves of the brake disks must be in a line. | |||
32 | Remove assembly device (73) from transmission (72) and place transmission (72) horizontally | ||
Assembly device | |||
33 | Determine shim for shift piston of splitter group | ||
Adjustment dimension for gearshift piston of cascade box | |||
34 | Pull out splitter group shift rod using assembly tool | ||
| Assembly tool for installing splitter group shift rod | ||
35 | Install rubber sealing ring and shift piston | Coat rubber sealing ring with synthetic grease. | |
Shift piston to splitter group shift rod | |||
Synthetic grease 50 g | |||
Quick-acting adhesive, Loctite 270 | |||
Puller | |||
36 | Determine shim for shift cylinder of splitter group | ||
Coat sealing rings with synthetic grease. | |||
Adjustment dimension for splitter box shift cylinder | |||
Synthetic grease 50 g | |||
Internal extractor | |||
Counter stay | |||
37 | Install countershaft brake compressed air line (25) at front section of transmission housing (7) | ||
38 | Remove holding device for shift rails (29, 30) | ||
39 | Install gearshift system (22) | ||
40 | Install oil restrictor (69) on main shaft (19) | ||
41 | Assemble range group (14) | ||
42 | Install range group (14) | ||
43 | Install transmission oil temperature sensor (B47) | Transmission oil temperature sensor to transmission housing | |
44 | Install countershaft speed sensor (B3) | Rpm sensor (countershaft) to transmission housing | |
45 | Install lines to electrical connections and brackets | ||
46 | Install release lever | Release lever to transmissionRelease lever to transmission |
715 589 08 31 00
Assembly device
715 589 03 15 00
Alignment punch
000 589 30 33 00
Internal extractor
714 589 05 15 00
Drift
001 589 80 21 00
Torque screwdriver
715 589 02 07 00
Puller
715 589 09 15 00
Drift
715 589 01 31 00
Retaining device
715 589 18 63 00
Retainer
715 589 15 63 00
Clamping plates
000 589 34 33 00
Counter stay
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 |