Remove/install shift rod and shift piston for splitter group

AR26.35-W-1000A

Remove/install shift rod and shift piston for splitter group

16.6.10

27.10.05

Document revised

4.1.06

Shift piston to splitter group shift rod

Transmission 715.515/525

*BA26.35-N-1002-01KL

Shift piston to splitter group shift rod

*BA26.35-N-1002-01A



Removing

1

Remove splitter sensor (B62)

 Only on vehicles with code (GS2) Gear control or with code (GS7) Gear control II or with code (GE3) Mercedes PowerShift.

2

Remove shift cylinder (1) of splitter group

AR26.18-W-1000A

3

Unscrew screw plug (6), remove springs (7, 8) and catch bolt (9)

 The screw plug (6) is spring-loaded.

4

Unscrew both bearing pins (5)

 Extraction claw

*715589063300

Impact extractor

*355589016300

5

Pull out shift rod (4) with shift piston (2)

 To remove, tilt shift fork and twist shift rod (4).

6

Detach rubber sealing ring (3)

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

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

AS00.00-Z-0002-01A

7

Heat up shift piston (2) to approx. 80 °C and detach from the shift rod (4) and remove shim (11)

 Pronged wrench

*715589020700

 Holding device

*715589003100

8

Remove radial shaft sealing ring and pilot bushing for shift rod (4)

AR26.35-W-1000-03A

 Internal extractor

*000589273300

 Countersupport

*000589333300



Adapter for removing guide bush in front section of transmission housing

WF58.50-N-1000-01A



Install

9

Install radial shaft sealing ring and pilot bushing for shift rod (4) of splitter group

AR26.35-W-1000-03A

 Drift

*714589051500

Synthetic grease

*BR00.45-Z-1027-06A

10

Install shift rod (4) using assembly tool (10) and attach shift fork in shift rod (4)

 Using a small screwdriver through the left bore of the bearing pin (5) hook up the shift fork in the shift rod.



Assembly tool for installing splitter group shift rod

WF58.50-N-2635-01A

11

Install bearing bolt (5)

 Secure bearing bolt (5) with quick-action adhesive.

*BR00.45-Z-1007-01A

 Transmission 715.500/507/ 510/513/517/
520/527/540

*BA26.35-N-1001-01A

 Transmission 715.370/380/515/525

*BA26.35-N-1001-01KL

12

Install screw plug (6) with springs (7, 8) and catch bolt (9)

 Coat screw plug (6) with sealant.

*BR00.45-Z-1015-01A

Transmission 715.500/507/ 510/513/517/520/527/540

*BA26.40-N-1008-01D

 Transmission 715.370/380/515/525

*BA26.40-N-1009-01KL

13

Determine shim (11) for shift piston (2) of splitter group

AR26.35-W-1000-01A

Transmission 715.500/507/ 510/513/517/
520/527/540

*BE26.35-N-1001-01A

Transmission 715.370/380/515/525

*BE26.35-N-1001-01KL

14

Pull shift rod (4) all the way out using the assembly tool (10)



Assembly tool for installing splitter group shift rod

WF58.50-N-2635-01A

15

Slide determined shim (11) onto shift rod (4)

16

Draw the rubber sealing ring (3) onto the shift piston (2) and install on the shift rod (4)

 Coat rubber sealing ring (3) with synthetic grease.

*BR00.45-Z-1027-06A

Secure shift piston (2) with quick-action adhesive.

*BR00.45-Z-1008-02A

 Transmission 715.500/507/ 510/513/517/520/527/540

*BA26.35-N-1002-01A

 Transmission 715.370/380/515/525

*BA26.35-N-1002-01KL

 Pronged wrench

*715589020700

17

Determine size of shim for shift cylinder (1) of splitter group

AR26.35-W-1000-02A

Transmission 715.500/507/ 510/513/517/
520/527/540

*BE26.35-N-1002-01A

Transmission 715.370/380/515/525

*BE26.35-N-1002-01KL

 Internal extractor

*000589303300

 Countersupport

*000589343300

Synthetic grease

*BR00.45-Z-1027-06A

18

Install splitter sensor (B62)

 Only on vehicles with code (GS2) Gear control or with code (GS7) Gear control II or with code (GE3) Mercedes PowerShift

 Transmission 715.500/507/510/513/

520/540

*BA26.19-N-1004-01A

 Transmission 715.370/380/515/525

*BA26.19-N-1002-01KL

Number

Designation

Transmission 715.500/507/
510/513/517/
520/527/540

BE26.35-N-1001-01A

Adjustment dimension for gearshift piston of cascade box

mm

0.3...0.5

BE26.35-N-1002-01A

Adjustment dimension for splitter box shift cylinder

mm

0.4...0.5

Number

Designation

Transmissions 715.370/380

Transmission 715.515/525

BE26.35-N-1001-01KL

Adjustment dimension for gearshift piston of cascade box

mm

0.3...0.5

0.3...0.5

BE26.35-N-1002-01KL

Adjustment dimension for splitter box shift cylinder

mm

0.4...0.5

0.4...0.5

Number

Designation

Transmission
715.500/507/510/513/520/540
with code GS7

Transmission
715.500/507/510/513/520/540
with code GS2

BA26.19-N-1004-01A

Splitter sensor to transmission housing

Nm

60

60

Number

Designation

Transmissions 715.370/380

Transmission 715.515/525

BA26.19-N-1002-01KL

Splitter sensor to transmission housing

Nm

60

60

Number

Designation

Transmission 715.500/507/510/
513/517/520/
527/540

BA26.35-N-1001-01A

Shift fork bearing bolt to transmission housing

Nm

120

BA26.35-N-1002-01A

Shift piston to splitter group shift rod

With special tool

Nm

90

Without special tool

Nm

95

Number

Designation

Transmissions 715.370/380

BA26.35-N-1001-01KL

Shift fork bearing bolt to transmission housing

Nm

120

BA26.35-N-1002-01KL

Shift piston to splitter group shift rod

With special tool

Nm

90

Without special tool

Nm

95

Number

Designation

Transmission 715.515/525

BA26.35-N-1001-01KL

Shift fork bearing bolt to transmission housing

Nm

120

BA26.35-N-1002-01KL

Shift piston to splitter group shift rod

With special tool

Nm

90

Without special tool

Nm

95

Number

Designation

Transmission 715.500/507/
510/513/517/
520/527/540

BA26.40-N-1008-01D

Splitter group shift lock to transmission housing

Nm

30

Number

Designation

Transmissions
715.370/380

Transmission 715.515/525

BA26.40-N-1009-01KL

Splitter group shift lock to transmission housing

Nm

30

30

Number

Designation

Order number

BR00.45-Z-1007-01A

Quick-action adhesive

A 003 989 31 71

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1008-02A

Quick-acting adhesive, Loctite 270

A 002 989 93 71

BR00.45-Z-1027-06A

Synthetic grease 50 g

A 001 989 32 51 10