Remove/install transmission

AR26.10-G-0020C

Remove/install transmission

19.08.2020

Transmission

718.841 in model 437.420/421/425/426/430/431/435/436/465

Shown on model 437.420

1

Compressed-air line

6

Screw

9.1

Torque ball housing

2

Pressure limiting valve

7

Screw

10

Bolts

3

Shield

8

Torque tube

11

Bolts

4

Drive shaft

8.1

Torque ball housing

12

Propeller shaft

5

Electrical wiring harness

9

Torque tube

13

Propeller shaft

5.1

Compressed air lines

Shown on model 437.420

14

Compressed-air line

15

Bracket

16

Bolts

17

Bolts

18

Right transmission bracket

19

Left transmission bracket

20

Bolts

21

Bolts

22

Right transmission bearing

23

Left transmission mount

24

Hook eyelet (only if removing transmission upward)

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A

 

Remove/install

1

Remove spare wheel.

Only for model 437.42/43

2

Remove spare wheel holder.

Only for model 437.42/43

3.1

Tilt cab to repair position.

For model 437.42/43

AR60.80-G-0005B

3.2

Remove body.

For model 437.465

 See information from body manufacturer.

4

Relieve pressure of compressed-air system.

5

Detach compressed-air line (1) at pressure limiting valve (2).

6

Detach both oil lines at transmission and collect escaping oil in a suitable container.

Only for vehicles with code G50 (Oil cooler)

7

Seal both oil lines using stop plugs.

Only for vehicles with code G50 (Oil cooler)

 Record plug

*129589009100

8

Remove shield (3).

If installed.

9

Detach drive shaft (4) from transmission.

 Screw/bolt, drive shaft to transmission flange

*BA26.10-N-1001-01H

10

Remove flexible exhaust pipe.

Only for model 437.421/426/431/436

11

Mark installation position of electrical wiring harness (5) relative to holders at transmission.

12

Detach electrical wiring harness (5) from transmission.

 Installation: Observe markings of electrical wiring harness (5).

13

Identify and disconnect all electrical connectors that are located on the electrical wiring harness (5).

 Installation: Pay attention to the markings on the electrical connectors.

14

Remove all compressed-air lines (5.1) at transmission.

AR42.10-G-0900BC

15

Loosen bleed lines of front and rear axle at transmission.

16

Remove screws (6, 7) of torque tubes (8, 9) at front and rear axle output shaft.

 Bolt, torque ball housing to transfer case

*BA33.30-N-1008-01F

 Rear axle 747.22/36Bolt, torque ball housing to transfer case

*BA35.30-N-1013-02C

17

Mark installation position of torque ball housings (8.1, 9.1) relative to transfer case.

18

Detach torque ball housings (8.1, 9.1) from transfer case.

 Installation: Observe the marked installation position. Clean sealing surfaces and coat with sealing compound.

Loctite 5203 sealant

*BR00.45-Z-1015-01A

19

Remove torque ball shell halves in torque ball housings (8.1, 9.1).

 Installation: Install torque ball shell halves again in the same position. Clean the torque ball shell halves and coat with long-life grease.

Long-life grease

*BR00.45-Z-1001-06A

20

Pull torque tubes (8, 9) back with chain hoists until screws (10, 11) of propeller shafts (12, 13) are accessible.

21

Insert one wooden block each between the torque tubes (8, 9) and the transmission.

22

Unscrew screws (10, 11) and remove propeller shafts (12, 13) at front axle and rear axle output shaft flange.


Do not allow torque tubes (8, 9) to hang; secure them instead.
Otherwise, the brake lines will be overstretched and damaged.

 Installation: Before positioning propeller shafts (12, 13) on transmission, insert previously determined and marked shims into torque ball housings (8.1, 9.1).

 Bolt, propeller shaft to front axle output flange

*BA41.10-N-1001-01J

 Bolt, propeller shaft to rear axle output shaft flange

*BA41.10-N-1002-01J

23

Pull torque tubes (8, 9) with propeller shafts (12, 13) away from front and rear axle output shaft using chain hoists.

 Secure torque tube (8, 9) against slipping back.

24

Remove compressed-air line (14) from air drier to air compressor.

 Only remove compressed-air line (14) from air drier up to first connecting point.

25

Remove holder (15) at transfer case.

Only for vehicles with hydraulic brake system.

26

Remove sensor for forward gear, reverse gear.

27

Remove shift cover.

Only if removing transmission downward.

AR26.30-G-6500B

28

Remove solenoid valves of range group cylinder.

29

Remove solenoid valves of forward and reverse gear reversing group.

30

Remove screws (16, 17) from right transmission bracket (18) and left transmission bracket (19).

 Screw/bolt, right transmission bracket to transmission

*BA26.10-N-1006-01H

 Screw/bolt, left transmission bracket to transmission

*BA26.10-N-1007-01H

31

Release screws (20, 21) on right transmission bracket (18) and left transmission bracket (19).

 Screw/bolt, right transmission bracket to transmission

*BA26.10-N-1006-01H

 Screw/bolt, left transmission bracket to transmission

*BA26.10-N-1007-01H

32.1

Attach hook eyelet (24) onto transmission from above.

If removing transmission upward.

 Clevis-type eyelet

*425589006200

32.2

Attach transmission removal fixture onto transmission from below.

If removing transmission downward.

 transmission removal device

*718589006100

33.1

Attach transmission to crane with hook eyelet (24), link chains, adaptation and load tilter.

If removing transmission upward.



000 588 02 62 00 Load tilter

WS01.00-N-0129B

 Link chains must each have a bearing strength of at least 500 kg.

 Adaptation

*936589016200

33.2

Attach pit hoist to transmission removal fixture from below.

If removing transmission downward.

34

Remove screws (20, 21) at right and left.

35.1

Remove transmission upward using crane.

If removing transmission upward.


During removal, check that all lines and component parts between the transmission and the frame are free of tension.
Otherwise damage could occur to the lines or components.

35.2

Remove transmission downward with pit hoist.

If removing transmission downward.


When lowering, check that all lines and component parts between the transmission and the frame are free of tension.
Otherwise damage could occur to the lines or components.

36

Retighten screws on right transmission mount (22) and left transmission mount (23) on frame.

 Screw/bolt, right transmission mount to frame

*BA26.10-N-1008-01H

 Screw/bolt, left transmission mount to frame

*BA26.10-N-1009-01H

Adjust

37

Clean sealing surfaces on torque ball housings (8.1, 9.1) and transfer case.

38

Adjust preload of torque tubes (8, 9) to torque ball housings (8.1, 9.1).

AR41.10-G-0020-03A

 Installation: Mark shims for torque ball housings (8.1, 9.1).
Insert determined shims between torque ball housings (8.1, 9.1) and transmission during installation of transmission.

 Installation flange

*425589005900

39

Install in the reverse order.



Check

40

Remove filling screw at transmission and check/correct oil level.

 The oil level is correct if the oil is a maximum of 10 mm below the filler opening.

 Transmission oil (synthetic oil)

*BF26.00-N-1001-01I

41

Screw in and tighten filling screw.

 Filling screw in transmission housing

*BA26.40-N-1005-01L

42

Carry out major teach-in process at control unit.

Only if transmission was replaced or repaired.

Model 437.42/43 except code G48 (Electronic automated gearshift (EAS)), model 437.465 up to 31.03.17 except code G48 (Electronic automated gearshift (EAS))

AR54.21-G-0007-02C

Model 437.42/43 with code G48 (Electronic automated gearshift (EAS)), model 437.465 up to 31.03.17 with code G48 (Electronic automated gearshift (EAS))

AR54.21-G-0007-02CC

Model 437.465 as of 01.04.17 as of vehicle identification end number 248687

AR26.21-G-2100CM

43

Teach in rpm sensor for speed.

Only carry out if rpm sensor for speed was replaced.

 In Germany in accordance with § 57b of German Regulations Authorizing the Use of Vehicles for Road Traffic (StVZO).

44

Perform tachograph inspection.

Only carry out if rpm sensor for speed was replaced.

 In Germany in accordance with § 57b of German Regulations Authorizing the Use of Vehicles for Road Traffic (StVZO).

45

Conduct a road test.

Update Vehicle Documentation (VeDoc)

46

Document transmission number in VeDoc.

Only when transmission has been replaced.

 Manual transmission, complete

Number

Designation

Transmission 718.841 in model 437.420/421/425/426/430/431/435/436/465

BA26.10-N-1001-01H

Screw/bolt, drive shaft to transmission flange

Nm

57

 Manual transmission, complete

Number

Designation

Transmission 718.841 in model 437.420/421/425/426/430/431/435/436/465

BA26.10-N-1006-01H

Screw/bolt, right transmission bracket to transmission

Nm

150

 Manual transmission, complete

Number

Designation

Transmission 718.841 in model 437.420/421/425/426/430/431/435/436/465

BA26.10-N-1007-01H

Screw/bolt, left transmission bracket to transmission

M16x1.5

Nm

340

M18x1.5

Nm

-

 Manual transmission, complete

Number

Designation

Transmission 718.841 in model 437.420/421/425/426/430/431/435/436/465

BA26.10-N-1008-01H

Screw/bolt, right transmission mount to frame

Nm

180

 Manual transmission, complete

Number

Designation

Transmission 718.841 in model 437.420/421/425/426/430/431/435/436/465

BA26.10-N-1009-01H

Screw/bolt, left transmission mount to frame

Nm

180

 Housing

Number

Designation

Transmission 718.841

BA26.40-N-1005-01L

Filling screw in transmission housing

Nm

70

 Front axle drive

Number

Designation

Front axle 737.220/221/222/224 with transmission 718.841

Front axle 737.365/375 with transmission 718.841

BA33.30-N-1008-01F

Bolt, torque ball housing to transfer case

Nm

55

60

 Front axle drive

Number

Designation

Front axle 737.366/376 with transmission 718.841

Front axle 737.367/368 with transmission 718.841

BA33.30-N-1008-01F

Bolt, torque ball housing to transfer case

Nm

60

60

 Rear axle drive

Number

Designation

Rear axle 747.220

Rear axle 747.221/222/224

BA35.30-N-1013-02C

Bolt, torque ball housing to transfer case

Nm

55

55

 Rear axle drive

Number

Designation

Rear axle 747.365

Rear axle 747.366

BA35.30-N-1013-02C

Bolt, torque ball housing to transfer case

Nm

60

60

 Rear axle drive

Number

Designation

Rear axle 747.367/368

BA35.30-N-1013-02C

Bolt, torque ball housing to transfer case

Nm

60

 Propeller shaft

Number

Designation

Model 437.4

BA41.10-N-1001-01J

Bolt, propeller shaft to front axle output flange

Nm

100

 Propeller shaft

Number

Designation

Model 437.4

BA41.10-N-1002-01J

Bolt, propeller shaft to rear axle output shaft flange

Nm

100

 Manual transmission

Number

Designation

TRANSMISSION 718.841 except CODEG20

TRANSMISSION 718.841 with CODE G20

BF26.00-N-1001-01I

Transmission oil (synthetic oil)

Filling capacity

Liter

11

13

Sheet

BB00.40-P-0235-41A

BB00.40-P-0235-41A

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10