Remove/install transmission

AR26.10-D-0020F

Remove/install transmission

8.5.09

 

Remove/install

1

Apply parking brake

2

Move gearshift lever to neutral

3

Remove exhaust heat shield (11)

4.1

Disconnect connections on PTO

With power take-off, code N05/ N07.

AR26.45-D-0010-04A

 Slave cylinder

*BA26.45-N-1003-01A

 Bracket for hydraulic line

*BA26.45-N-1004-01A

 Propeller shaft

*BA41.20-N-1001-01A

5

Detach locking bracket (7)



*BA41.10-N-1004-01B

6

Take off propeller shaft (10) at transmission

 Move propeller shaft to right and tie up.



*BA41.10-N-1001-01B



Notes on installing propeller shaft

Model 690.6, 901, 902, 903, 904, 905

AH41.10-N-0001-01A

 Installation: Only with all-wheel drive, Code ZG1/ ZG2/ ZG3

Align transfer case with transmission

AR28.10-D-0500A

7

Support engine

 Insert wooden block between oil pan and crossmember (arrow A)



Wooden block for supporting engine

Engine 611 and 111

WF58.50-N-2610-01A



Wooden block for supporting engine

Engine 612

WF58.50-N-2610-01B

8

Remove speedometer sensor (4)

 Installation: Attach tamper-proof seal to speedometer sensor.



*BA26.40-N-1009-01A

9

Disconnect connector (3) on backup lamp switch

10

Disconnect shift cables (1, 2) from transmission

AR26.60-D-6627-01A

11

Detach line bracket (18) from transmission housing

12

Clamp off hydraulic line (15) to central clutch operator using hose clamp pliers (19) on the flexible part

 Clamping device

*000589543700

Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

13

Remove spring clip (21) and disconnect plug connection on hydraulic line (15) to central clutch operator

 Collect escaping hydraulic fluid (brake fluid) with a suitable container. Tie line back to one side.

 Installation: Replace O-ring (16).



Brake fluid notes

All models

AH42.50-P-0001-01A

14

Remove starter

 Installation: Use upper bolt to attach vent hose bracket (20).



*BA26.10-N-1001-01A

15

Tie back vent hose bracket (20) to one side

16

Disconnect ground strap (22) and tie back to one side



*BA26.10-N-1001-01A

17

Remove hexagon bolts (23) on underside of transmission

 Two hexagon bolts (23) on top of transmission must remain in the housing



*BA26.10-N-1001-01A

18

Place hydraulic transmission jack under transmission and raise slightly

 Secure transmission on hydraulic lifting equipment using a tensioning strap or with the assistance of another person

19

Remove rear engine crossmember (26)

 First unscrew the hexagon nuts (27) at the outside ends of the engine cross member. Unscrew middle hexagon nuts (25) at transmission last.

 Rear engine crossmember to bearing bracket (engine 611.981/983/987 and engine 612.981)

*BA22.10-N-1004-01L

 Rear engine mount to transmission
(engine 611.981//983/987 and engine 612.981)

*BA22.10-N-1005-01L

 Rear engine crossmember to bearing bracket (engine 111.984)

*BA22.10-N-1007-01H

 Rear engine mount to transmission
(engine 111.984)

*BA22.10-N-1008-01H

20

Remove last hexagon bolts (23) at upper side of transmission



*BA26.10-N-1001-01A

21

Draw out transmission towards the rear and lower

 Installation: Ensure that the dowel bolts are fitted correctly.

22

Install in the reverse order

23

Adjust shift cables

AR26.60-D-0635-02A

24

Bleed clutch operating system

AR25.20-D-0070A

25

Check that transmission shifts properly with the vehicle stationary first

26

Conduct a road test

Number

Designation

Engine 111.984

BA22.10-N-1007-01H

Rear engine crossmember on bearing bracket

Nm

45

BA22.10-N-1008-01H

Rear engine mount on transmission

M121.5

Nm

89

Number

Designation

Engine 611.981/
983/987

Engine 612.981

BA22.10-N-1004-01L

Nut/bolt, rear engine crossmember to console

Nm

45

45

BA22.10-N-1005-01L

Bolt, rear engine mount to transmission

Nm

89

89

Number

Designation

Trans-mission 711.605

Trans-mission 711.620/
621

BA26.10-N-1001-01A

Bolt connecting manual transmission to engine

Nm

38

38

Number

Designation

Trans-mission
711.605

Trans-mission
711.620/
621

BA26.40-N-1009-01A

Speedometer sensor to transmission housing

Nm

14

14

Number

Designation

PTO 28-2c with output flange code N07 with
transmissions 711.612/613

PTO 28-2c without output flange code N05 with
transmissions 711.612/613

PTO 28-2b with output flange code N07 with
transmissions 711.620/621

BA26.45-N-1003-01A

Slave cylinder on power takeoff

Nm

13

13

13

BA26.45-N-1004-01A

PTO hydraulic line bracket to transmission housing

Nm

55

55

38

Number

Designation

Model
690.6, 901, 902, 903, 904, 905 except Minibus Sprinter Low Floor

BA41.10-N-1001-01B

Propeller shaft on transmission

M101

Stage 1

Nm

70

Stage 2

°

-

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

M121.5

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

Screw headE18

Stage 1

Nm

-

Stage 2

°

-

BA41.10-N-1004-01B

Bolt, retaining bracket to frame floor

M121.5

Nm

100

Number

Designation

PTO 28-2b (with output flange Code N07) with transmission 711.612 in model 901, 903, 904.0/4

PTO 28-2b (with output flange code N07) with transmission 711.620 in model 901.6, 902.6, 903.6, 904.6

BA41.20-N-1001-01A

Propeller shaft to PTO

Stage 1

Nm

23

23

Stage 2

°

-

-