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Note: Since illustrations are used for several different variants, certain details may differ from the variant in question.The essential information in the illustrations is, however, always correct.
A. Position sensor for range cylinderB. Countershaft speed sensorC. Main shaft speed sensorD. Position sensor, 2nd and 3rd cylinderE. Position sensor 1st and reversecylinderF. Position sensor split cylinder
R. Range cylinder2/3. 2/3 cylinder1/R. 1/R cylinderS. Split cylinder
Special tools: 9998588
1
Read off X1 value with the PC-tool or from the label, note X1 value.This is in case the upper cover needs to be replaced. Remove all electrical connections (4) for the
Loosen the upper edge of the cover and carefully fold down towards the bench. Remove theelectrical connector carefully to avoid damaging the electrical cabling.
7
Remove the seals for the solenoid valves, the O-ring for the countershaft brake and the covergasket.
Remove the piston and sealing ring from the back of the split cylinder.
14
Remove the front cover for the 1/R cylinder, undo the rear cover and pull out the selector fork withcovers and piston.
Note: The 2nd/3rd selector fork shall be in neutral position, so that the inhibitor pin for 1st/R and 2nd/3rd cylinders does.not lock the front cover in place
Remove the piston from the back of the 2nd/3rd cylinder.
18
Remove the cover for the range cylinder. Pull out the piston carefully, so that the piston rod seal isnot damaged.
Note: The bush and seal in the rear end plate of the range cylinder cannot be replaced separately and must thereforebe left in place.
19Clean the housing, check constituent parts. Change any damaged parts.None of the seals or bushes in any of the covers can be replaced separately, therefore the wholecover must be changed.
Note: Blow clean the air passages between the cylinders and solenoid valves thoroughly.When assembling, all piston surfaces, piston sliding surfaces and sealing rings must be greased.
Press out the spring pin for the 2nd/3rd selector fork. Use a drift and a sleeve as counterhold.Remove the selector fork (carefully tap the spring pin out of the selector fork).
Note: Spring and pin for the position sensor.
Special tools: 9998588
23Remove the cover and piston from the piston rod.
24Fit a new piston and a new O-ring into the cover. Fit the cover onto the piston rod.
Fit position sensor pins and springs to the selector fork.
26
Fit the 2nd/3rd selector fork onto the piston rod, press the piston rod to the bottom of the fork andcarefully press in the spring pin using a drift with a sleeve as support.
Note: The opening in the spring pin must be facing the cover and lengthwise in relation to the piston rod.
Fit the 2nd/3rd selector fork with cover and piston into the 2nd/3rd cylinder. Fit the piston and rearcover with a new O-ring. Torque tighten the screws.
Specifications:18±1.5 Nm
28Fit a new O-ring to the rear split cover. Fit the piston into the cylinder with a new piston seal. Fit therear cover and torque tighten the screws.
Note: This must be done now, because it is not possible to torque tighten the screws later.
Press out the spring pin for the 1st/R selector fork. Use a drift and a sleeve as counterhold.Remove the selector fork (carefully tap the spring pin out of the selector fork).
Special tools: 9998588
30Remove the cover and piston from the piston rod.
31Fit a new piston onto the piston rod and a new O-ring onto the cover.
Fit a new piston to the front of the cylinder for the 1st/R cylinder.
35
Fit a new O-ring into the front cover of the 1st/R cylinder. Fit the locking pin into the cover.Fit the cover and torque tighten the screws.
Specifications:18±1.5 Nm
36Put the 2nd/3rd selector fork in neutral position and press in the locking pin against the 2nd/3rdselector fork so that it engages in the groove for neutral.
37Fit the selector fork with piston and cover into the 1st/R cylinder. Torque tighten the screws.
Press the spring pin carefully out of the split selector fork. Use a drift and a sleeve as counterhold.Remove the selector fork (carefully tap the spring pin out of the selector fork).
Special tools: 9998588
39
Remove the cover and change all the sealing rings on the pistons.
Turn the control housing so that it is standing on the selector forks. Fit new screws to the cover (6off M8x30, included in repair kit) and torque tighten.
Specifications:24±4 Nm
50
Turn the control housing so that the upper cover is against the bench.Fit the attachment plate for the electrical cable. Connect the electrical cable to the position sensors.
Note: The electrical cable must lie inside the lug on the range cylinder.
52Perform a functional test .Gear test, removed gearbox, in the PC-tool
Note: Carry out the test with the control housing lying on the upper cover. The control housing must not be touched.during the test, due to the risk for injury
Once the control housing has been fitted to the gearbox, calibration must be performed. If the cover has been changed,the noted value for X1 must be entered into the control unit.