Disassemble/assemble gearshift system

AR26.60-W-6515A

Disassemble/assemble gearshift system

16.6.10



Disassemble

1

Remove shift mechanism

AR26.60-W-0001B

2

Remove gearshift housing (19) from gearshift housing flange (6)

3

Remove radial shaft seal (21) from shift housing (19)

 Use a suitable drift.

AR26.60-W-0001-02A

4

Remove needle bearing (20)



*000589293300



*000589343300

5

Remove retaining ring (26) and take out stop plug for emergency running mode (23)

6

Detach locking ring (18) from shift shaft (1)

 Push shift housing flange (6) against shift shaft (1) to take the load off the locking ring (18).

7

Pull shift shaft (1) out of shift hub (14)

8

Pull shift hub (14) out of shift housing flange (6) and remove index bolt (13) with spring (12)

 The index bolt (13) is spring-loaded.

9

Remove needle bearing (5)

AR26.60-W-0001-01A



*000589283300



*000589343300

10

Compress spring (16)



Spring compressor for shift mechanism in manual transmission

WF58.50-N-6515-01A

11

Remove circlip (17)

12

Remove spring (16) and washers (15)

13

Unscrew grub screws (11) and detach notch lever (10)

 The grub screws (11) are secured with locking agent. Heat notch lever (10).

14

Remove roll pin (2)

 Use a suitable drift.

15

Pull off shift finger (3) and locking bar (4)

 Identify installation position of the locking bar (4)

16

Remove detent segment (8)



Assemble

17

Install detent segment (8)

 The cutout (arrow) on the detent segment (8) must point toward the input shaft.

Install bolt (9) with locking agent.

*BR00.45-Z-1008-02A



*BA26.60-N-1003-01D

18

Insert spring (16) and washers (15) into shift hub (14)

19

Compress spring (16)



Spring compressor for shift mechanism in manual transmission

WF58.50-N-6515-01A

20

Install circlip (17).

21

Install needle bearing (5) in shift housing flange (6)

 Use a suitable drift.

AR26.60-W-0001-01A

22

Mount notch lever (10) on the shift hub (14) and fit new grub screws (11)

 The grub screws (11) are only tightened when the shift finger (3) is adjusted.

*BR00.45-Z-1008-02A

23

Install shift hub (14) with index bolt (13) and spring (12) in the shift housing flange (6)

 The index bolt (13) must engage in the detent segment (8), press back the index bolt (13).

24

Push the shift finger (3) and plunger block (4) onto the shift shaft (1)

 Observe installation position of shift finger (3) and plunger block (4).

25

Install roll pin (2)

 Use a suitable drift.

26

Insert shift shaft (1) into shift hub (14)

 The shift shaft (1) must be installed into the shift hub (14) offset by approx.  4° and point towards the output.
Grease the splines of the shift shaft (1) with long-life grease.

*BR00.45-Z-1001-06A

27

Install circlip (18).

 Press the shift housing flange (6) against the shift shaft (1) until the groove for the circlip (18) is free.

28

Adjust shift finger (3)

AR26.60-W-0001-03B



*BA26.60-N-1004-01D



*116589020700



*715589042100

29

Install needle bearing (20)

 Use a suitable drift.

30

Install radial shaft sealing ring (21)

 Use a suitable drift.

31

Install shift mechanism in shift housing (19)

32

Insert stop plug for emergency running mode (23) and install retaining ring (26).

 Replace sealing ring (22).

33

Install shift linkage.

AR26.60-W-0001B

Number

Designation

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

BA26.60-N-1003-01D

Detent segment to shift housing

Nm

25

BA26.60-N-1004-01D

Grub screw in notch lever

Nm

33

Number

Designation

Order number

BR00.45-Z-1008-02A

Quick-acting adhesive, Loctite 270

A 002 989 93 71

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11