Disassemble/assemble gearshift system

AR26.60-W-6515D

Disassemble/assemble gearshift system

16.6.10



Disassemble

1

Remove shift mechanism

AR26.60-W-0001D

2

Remove solenoid valve (17)

3

Detach washer (10) and locking ring (9) from shift hub (4)

4

Unscrew grub screws (14), remove notch lever (8) with springs (11, 12) and index bolt (13) from the shift hub (4)

 The grub screws (14) are secured with locking agent, heat up threaded pins (14) if necessary.
The index bolt (13) is spring-loaded.

5

Remove shift hub (4) from shift housing (7)

6

Remove locking ring (1) from shift hub (4) and take out washers (2) and spring (3)

 The circlip (1) is spring-loaded.

7

Remove radial shaft sealing ring (5) from shift housing (7)

 Use a suitable drift.

8

Remove needle bearing (6) from shift housing (7)



*000589283300



*000589343300

9

Unscrew bolt (15) and remove detent segment (16)

10

Unscrew grub screw (30) and remove thrust piece (31) from the shift shaft (21)

 The grub screw (30) is secured with locking agent. Heat up the grub screw (30) for removal.
Identify the installation position of the thrust piece (31).

11

Pull shift shaft (21) out of bearing cover (32)

 Collect balls (22) with a cloth. Ensure that none of the 6 balls (22) is missing.

12

Remove gate detent bush (28)

 Mark installed position.

13

Drive out roll pin (18), remove shift finger (19) and locking bar (20)

 Use a suitable drift.
Identify installation position of locking bar (20).

14

Remove circlip (27) from the shift shaft (21), remove springs (24), thrust pieces (25) and bushes (23, 26)

 The circlip (27) is spring-loaded.

15

Drive out roll pin (34) and remove locking pin (33) from bearing cover (32)

 Use a suitable drift.

16

Remove needle bearing (29) from bearing cover (32)



*000589283300



*000589343300



Assemble

17

Install needle bearing (29) in bearing cover (32)

 Use a suitable drift.
Grease needle roller bearing in (29) with long-life grease.

*BR00.45-Z-1001-06A

18

Install locking pin (33) in bearing cover (32) and drive in roll pin (34)

 Use a suitable drift.
The recess in the locking pin (33) must point towards the output end.

19

Insert bushes (23, 26), springs (24) and thrust pieces (25) into shift shaft (21) and install locking ring (27)

 Insert circlip (27) and using a suitable pipe press in until it engages.

20

Insert shift finger (19) into locking bar (20) and push onto shift shaft (21) together

 Observe installation position of locking bar (20).

21

Drive in roll pin (18)

 Use a suitable drift.

22

Fit detent segment (16) and tighten bolt (15)

 Install bolt with locking agent.

*BR00.45-Z-1008-02A



*BA26.60-N-1003-01D

23

Install needle bearing (6) in shift housing (7)

 Use a suitable drift.
Grease needle roller bearing in (6) with long-life grease.

*BR00.45-Z-1001-06A

24

Install radial shaft sealing ring (5) into shift housing (7)

 Use a suitable drift.
Coat lip of radial shaft seal (5) with long-life grease.

*BR00.45-Z-1001-06A

25

Install washers (2), spring (3) and locking ring (1) in shift hub (4)

26

Install shift hub (4) in shift housing (7)

27

Push notch lever (8) with springs (11, 12) and index bolt (13) onto shift hub (4) and tighten grub screws (14) a little

 Coat index bolts (13) with long-life grease.

The position of the grub screws (14) must align with the countersinks in the shift hub (4).

*BR00.45-Z-1001-06A

28

Install circlip (9)

 Install the washer (10) just before installing the shift mechanism in the transmission.

29

Insert shift shaft (21) into shift hub (4)

30

Adjust shift finger (19)

AR26.60-W-0001-03C



*116589020700



*715589042100

31

Insert bush of gate detent (28) in the bearing cap (32)

 The small diameter of the bush for the gate detent (28) must point towards the locking pin (33) (arrow).

32

Insert balls (22) into shift shaft (21) and push shift shaft (21) into bearing cover (32)

33

Push on thrust piece (31) and tighten grub screw (30)

 The long side of the thrust piece (31) must point towards the bearing cap (32). Secure the grub screw (30) with locking agent.

*BR00.45-Z-1008-02A



*BA26.60-N-1005-01D

34

Install solenoid valve (17)

 Replace all sealing rings.

35

Install shift linkage.

AR26.60-W-0001D

Number

Designation

Transmission 715.500/507/510/513/520/540
with code GS3 without code IY2

BA26.60-N-1003-01D

Detent segment to shift housing

Nm

25

BA26.60-N-1005-01D

Grub screw in thrust piece

Nm

15

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