Chassis serial number: 5509074

05-10 Shafts, gears and synchromeshes GRSO

905
Dismantling - Input shaft
Tools

Number Designation Illustration Tool board

99 136 Hollow drift PT1

99 141 Support ring PT1

587 312 Circlip pliers G1

1. Remove the 2 piston rings.

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 Chassis serial number: 5509074

2. Remove the retaining ring with 587 312 Circlip

pliers.
Put something soft into 99 136 Hollow drift and
fit 99 141 Support ring. Press out the bearing,
needle bearing and gear.

1 2

587 312 99 141

99 136

Assembly - Input shaft

Tools

Number Designation Illustration Tool board

98 334 Counterholding tube G3

98 636 Assembly drift G1

587 312 Circlip pliers G1

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 Chassis serial number: 5509074

1. Place the shaft on a press bench, fit needle

bearing halves and gear, and press the bearing
into place with 98 334 Counterholding tube and
98 636 Assembly drift.
Fit the retaining ring with 587 312 Circlip
pliers. Fit a retaining ring that is as wide as
possible and make sure it completely reaches
the bottom.
Retaining rings are available in the following
dimensions:

Width Mark

4.14 mm (± 0.015 mm) Yellow

4.10 mm (± 0.015 mm) Blue

4.06 mm (± 0.015 mm) White

4.02 mm (± 0.015 mm) Red

4.00 mm (+0 mm -01 mm) Unmarked

3.98 mm (± 0.015 mm) Green

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 Chassis serial number: 5509074

2. Fit the two piston rings. 1

Dismantling - Mainshaft
Tools

Number Designation Illustration Tool board

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 Chassis serial number: 5509074

Number Designation Illustration Tool board

87 237 Support drift G2

98 257 Support drift AM2

99 136 Hollow drift PT1

99 154 Support drift N/A

99 202 Support ring PT1

587 600 KM socket, 80.4 mm, 3/4" N/A

2 587 983 Puller plate, 22-115 mm XA1

2 587 985 Puller plate, 30-155 mm XA1

2 587 988 Bearing puller, 60-215 mm XA1

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 Chassis serial number: 5509074

Number Designation Illustration Tool board

2 587 989 Bearing puller, 85-295 mm XA1

2 588 010 Puller, 2 arm, 80-350 mm XA3

Long extra arms for XA3

2 588 012
2 588 010

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 Chassis serial number: 5509074

1. Information! The bearing will be damaged 2 587 988 2 587 983

during removal and must be replaced by a new
one during fitting. 87 237

Put the shaft on a workbench and pull off the

bearing with 2 587 983 Puller plate, 22-115
mm, 2 587 988 Bearing puller, 60-215 mm and
87 237 Support drift. Turn 2 587 983 Puller
plate, 22-115 mm so that the flat side faces the
bearing.
Loosen the nut using nut runner and 587 600
KM socket, 80.4 mm, 3/4" but do not remove it
from the shaft.

2. Pull off the gears for the reverse and crawl gear 2 588 010
with 2 588 010 Puller, 2 arm, 80-350 mm,
2 588 012 Long extra arms for 2 588 010 and
99 154 Support drift. Remove the coupling
sleeve.
99 154
2 588 012

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 Chassis serial number: 5509074

3. Lift the shaft over to a press. Undo the nut, put

something soft under the shaft in 99 136 Hollow
drift and press out the shaft with 99 202 Support 98 257
ring and 98 257 Support drift. The drop below
the hollow drift should be at least 5 cm.
Hold together and mark the splitter gearwheel
and its bearing if the components are to be
reused.

99 202
99 136

4. Pull off the crawl gear race with 2 587 985 2 587 989 2 587 985
Puller plate, 30-155 mm, 2 587 989 Bearing
puller, 85-295 mm and 99 154 Support drift.

99 154

Assembly - Mainshaft
Tools

Number Designation Illustration Tool board

99 009–1 Drift AD/AS3

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 Chassis serial number: 5509074

Number Designation Illustration Tool board

87 089 Drift AM2, S3.1

87 550 Drift AD/AS2

87 921 Drift R1

Pull rod, 1,000 mm, G2

88 292
Ø25mm

98 075 Dial gauge D2, MB3

98 334 Counterholding tube G3

99 132 Drift R2

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 Chassis serial number: 5509074

Number Designation Illustration Tool board

99 144 Support ring PT1

99 190 Drift G4

99 201 Support ring PT1

99 207 Press drift G4

99 450 Support ring PT1

99 558 Dummy bearing G3

99 559 Counterhold G3

Indicator stand with

587 250 precision MB3
adjustment

KM socket, N/A
587 600
80.4 mm, 3/4"

2 309 000 Drift AD2

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 Chassis serial number: 5509074

1. 1. Put the shaft on the press bench in tools

99 450 Support ring and 99 144 Support
ring as illustrated. Press on the race for the
crawl gear with 87 550 Drift and 2 309 000
Drift.
2. Fit needle bearings. Fit the crawl gear
wheel with the coupling teeth facing
upwards. Tap down the driver. Fit the
coupling sleeve. Press in the reverse gear
race with 2 309 000 Drift and 98 334
Counterholding tube.
3. Fit needle bearings and the reverse shaft
gear with the coupling teeth facing
downwards. Fit the spacing ring or pulse
wheel for Opticruise with the concave side
facing upwards. Fit the mainshaft rear
bearing. Centre 99 190 Drift carefully so
that it does not make contact with the shaft
and press the bearing into place.

1 2 3
87 550

98 334
99 190

2 309 000

2 309 000
99 450

99 144

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 Chassis serial number: 5509074

2.
IMPORTANT!

The shafts should be rotated when adjusting the

axial clearance. The friction surfaces of the
synchromeshes must be oiled to make rotation
easier.

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 Chassis serial number: 5509074

3. Fit the synchromesh for first gear.

Turn the shaft, lubricate the friction surfaces
and fit the triple synchromesh as illustrated.
1. Fit the driver.
2. Insert the wire spring into the driver.
3. Press on the coupling sleeve.
4. Fit a new latch cone and align it with the
driver. See illustration.
5. Fit a new middle cone. See illustration.
6. Fit the inner cone and align it with the
driver. It only fits in one position.
7. Fit the coupling cone.
Use 99 144 Support ring and 99 201 Support
ring.

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 Chassis serial number: 5509074

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 Chassis serial number: 5509074

1 7 6 5 4 2 3

99 201
99 144

C D
The middle cone C is 0.8 mm longer and
the latch cone lugs D have been extended
0.8 mm.

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 Chassis serial number: 5509074

4. 1. Fit needle bearings and first gear wheel

with the coupling teeth facing downwards.
Fit 99 201 Support ring on 99 144 Support
ring and press in the second gear race in 2
steps. Start pressing with 98 334
Counterholding tube to align the race.
2. Continue pressing with 87 921 Drift and
2 309 000 Drift until the race is in place.
3. Fit needle bearings and the second gear
wheel with the coupling teeth upwards and
fit the synchromesh hub. Press one of the
splitter gearwheel bearings into place in
accordance with the marks made earlier
with 99 190 Drift.

1 2 3

99 190
98 334

98 334

2 309 000

99 201
99 144

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 Chassis serial number: 5509074

5. Checking and adjusting bearing play on the

mainshaft splitter gearwheel
• Fit the splitter gearwheel on the bearing.
• Fit 99 201 Support ring on 99 144 Support
ring first and then the shims. When
measuring the clearance, you should start
with too much clearance. Therefore fit one
shim more than before.
• Put 99 558 Dummy bearing in the splitter
gearwheel and press it down with 99 190
Drift. Rotate the gearwheel while pressing
it down. Stop pressing if it is hard to rotate
the wheel and switch to thicker shims.
• Press with 10 kN, rotate a few turns,
always in the same direction, while
pressing down the gearwheel. Fit 587 250
Indicator stand with precision adjustment
with 98 075 Dial gauge and zero the dial
gauge.
• Lift the gearwheel using 2 screwdrivers
and read the dial gauge.
• Mark the measuring point on the gear,
rotate as above and take readings 3 times at
the same measuring point. Take the
average.
• Correct measurement: 0.03-0.09 mm.
• Remove the dummy bearing and adjust the
thickness of the shims. Refit the dummy
bearing and repeat the measurement.

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 Chassis serial number: 5509074

587 250

99 190

99 558

98 075
0.03 - 0.09 mm

99 201
99 144

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 Chassis serial number: 5509074

6. Checking and adjusting bearing play on the

mainshaft splitter gearwheel
• Fit the splitter gearwheel on the bearing.
• Fit the spacing ring first and then the
shims. When measuring the clearance, you
should start with too much clearance.
Therefore fit one shim more than before.
• Put 99 558 Dummy bearing in the splitter
gearwheel and press it down with 99 190
Drift. Rotate the gearwheel while pressing
it down. Stop pressing if it is hard to rotate
the wheel and switch to thicker shims.
• Press with 10 kN, rotate a few turns,
always in the same direction, while
pressing down the gearwheel. Fit 587 250
Indicator stand with precision adjustment
with 98 075 Dial gauge and zero the dial
gauge.
• Lift the gearwheel using 2 screwdrivers
and read the dial gauge.
• Mark the measuring point on the gear,
rotate as above and take readings 3 times at
the same measuring point. Take the
average.
• Correct measurement: 0.03-0.09 mm.
• Remove the dummy bearing and adjust the
thickness of the shims. Refit the dummy
bearing and repeat the measurement.

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 Chassis serial number: 5509074

7. Fit the synchromesh for second and third

gears.
Remove the dummy bearing and splitter
gearwheel. Lubricate the friction surfaces and
fit the synchromesh for second and third gears
as illustrated.
1. Fit the coupling disc.
2. Fit the inner cone.
3. Fit the middle cone.
4. Fit the latch cone and align it with the inner
cone.
5. Insert the wire spring into the driver.
6. Fit the driver.
7. Insert the wire spring into the driver.
8. Press on the coupling sleeve.
9. Fit the latch cone and align it with the
driver. The latch cone only fits in two
positions in the driver.
10. Fit the inner cone.
11. Fit the coupling disc.
Use 99 144 Support ring and 99 201 Support
ring.

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 Chassis serial number: 5509074

6 11

10
5

4
9

8
2

1 7

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 Chassis serial number: 5509074

6 11 10 9 7 8

1 2 3 4 5

99 201
99 144

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 Chassis serial number: 5509074

8. Fit the splitter gearwheel and press in a new

bearing with 99 190 Drift.
Lock the upper gearwheel and shaft together by
engaging a gear. If necessary, secure the
coupling sleeve in the upper position using two
screws and nuts. Put 99 559 Counterhold and
88 292 Pull rod, 1,000 mm, Ø25mm on the
coupling teeth using the press strut as a
counterhold. Fit the press to the torque wrench
to hold the shaft in place and torque tighten the
nut with 587 600 KM socket, 80.4 mm, 3/4".

Mainshaft, round nut*

400 Nm
*Applies only to GRS895 GRS905, GRSO905,
GRSO925 and GRSO935.

1 2 400 Nm

88 292 587 600

99 190

99 559
M8X60

99 201
99 144

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 Chassis serial number: 5509074

9. • Lock the nut by upsetting it in 2 places, see

illustration 1.
• Use 99 144 Support ring and 99 201
Support ring.
• GRS-GRSO 905–925: For shaft with
diameter 42 mm. Press on the bearing with
press drift 99 207 Press drift.
• GR905: For shaft with diameter 50 mm.
Press on the bearing with 99 009–1 Drift.
• Other gearboxes: Press on the small
tapered bearing using the tool as illustrated.
Start pressing with 99 132 Drift to align the
bearing. Continue pressing with 87 089
Drift.

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 Chassis serial number: 5509074

10. Assembling the split synchromesh

Lubricate the friction surfaces and assemble the
split synchromesh and place it to one side. The
split synchromesh is fitted to the mainshaft in
conjunction with the assembly of the gearbox
front section.
1. Place the coupling disc on a workbench.
2. Fit the inner cone.
3. Fit the latch cone.
4. Insert the wire spring into the driver.
5. Fit the driver.
6. Insert the wire spring into the driver.
7. Press on the coupling sleeve.
8. Fit the latch cone and align it with the
driver. The latch cone only fits in two
positions in the driver.
9. Fit the inner cone.
10. Fit the coupling disc.

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 Chassis serial number: 5509074

10
5

9
4

7
2

1 6

10 9 8 6 7

5 1 2 3 4

Dismantling - Layshaft

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 Chassis serial number: 5509074

Tools

Number Designation Illustration Tool board

98 575 Support drift G2

98 647 Support drift G2

99 136 Hollow drift PT1

99 142 Support ring PT1

99 450 Support ring PT1

587 312 Circlip pliers G1

2 587 983 Puller plate, 22-115 mm XA1

2 587 988 Bearing puller, 60-215 mm XA1

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 Chassis serial number: 5509074

1. Information! The bearing will be damaged

during removal and must be replaced by a new
one during fitting.

Pull off both the layshaft bearings using the tool

as illustrated. Use 2 587 983 Puller plate, 22-
115 mm, 2 587 988 Bearing puller, 60-215 mm
and 98 647 Support drift.
98 647 98 647
2 587 988 2 587 988

2 587 983
2 587 983

2. 1. Remove the retaining ring with 587 312

Circlip pliers.
2. Place soft material inside 99 136 Hollow
drift to cushion the fall and press off the
front splitter gearwheel with 99 450
Support ring and 98 575 Support drift.

1 2 98 575
587 312
99 450

99 136

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 Chassis serial number: 5509074

3. 1. Press off the other splitter gearwheel with

99 136 Hollow drift, 99 450 Support ring
and 98 575 Support drift.
2. Press off the second gear with 99 136
Hollow drift, 99 142 Support ring and
98 575 Support drift

1 2
98 575
98 575
99 142
99 450

99 136 99 136

Assembly - Layshaft
Tools

Number Designation Illustration Tool board

98 575 Support drift G2

98 638 Assembly drift G3

99 190 Drift G4

99 191 Drift G4

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 Chassis serial number: 5509074

Number Designation Illustration Tool board

99 450 Support ring PT1

587 312 Circlip pliers G1

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 Chassis serial number: 5509074

1. Information! The press force must reach at

least 300 kN (30 tonnes) before each gear
reaches the bottom.

1. Place the second gear wheel on 99 450

Support ring, apply thread-locking fluid
561 200 to the shaft and press in the shaft
with 98 575 Support drift.
2. Place the rear splitter gearwheel on 99 450
Support ring, apply thread-locking fluid
561 200 to the shaft and press in the shaft
with 98 575 Support drift.
3. Place the front splitter gearwheel on 99 450
Support ring, apply thread-locking fluid
561 200 to the shaft and press in the shaft
with 98 575 Support drift.

1 2 3
98 575

98 575

98 575

99 450 99 450 99 450

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 Chassis serial number: 5509074

2. 1. Press on the rear bearing with 99 190 Drift.

2. Turn the shaft and fit the snap ring with
587 312 Circlip pliers.
3. Leave the shaft resting with a suitable gear
on the support in the press or place the
shaft on 99 191 Drift and press on the front
bearing with 98 638 Assembly drift.

1 2 3 98 638

99 190
587 312

99 191

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