Remove/install transmission

AR26.10-P-0020PI

Remove/install transmission

15.2.12

19.10.06

Transmission oil, filling capacity

Transmission 716.604

*BF26.10-P-1001-01C

 

Remove/install

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

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

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A



Brake fluid notes

AH42.50-P-0001-01A



Notes on battery

AH54.10-P-0001-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Disconnect battery ground line

Model 203

AR54.10-P-0003P

Model 209

AR54.10-P-0003Q

2

Remove bottom sections of soundproofing

AR94.30-P-5300P

3

Remove bracket of catalytic converter (2)

 To do this, unscrew the bolts on the transmission (1) and the nut on the catalytic converter.

 Nut, front exhaust system to bracket

*BA49.10-P-1001-01V

 Bolt of bracket of front exhaust system to transmission

*BA49.10-P-1002-01V

4

Remove bracket of exhaust system (3)

 To do this remove bolts on transmission (1) and nuts on exhaust system.

 Nut, front exhaust system to bracket

*BA49.10-P-1001-01V

 Bolt of bracket of front exhaust system to transmission

*BA49.10-P-1002-01V

5

Support and secure transmission (1)

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

Vehicle lift for major assemblies/scissors-type pallet forklift

gotis://A_01_07.1

Lashing strap as tilt control
gotis://H_00.1_05.2

6

Remove engine crossmember (4) with engine mount

 Do not detach the engine mount from the engine crossmember (4).

AR22.10-P-1160PI

7

Disconnect front propeller shaft at transmission (1)

 Installation: Check centering sleeve of propeller shaft, replace if necessary.

AR41.10-P-0050-02PI

Mount front propeller shaft to transmission

 Installation: Pack cavity in centering sleeve with multipurpose grease.

AR41.10-P-0050-07PI

 Self-locking nut, flexible coupling to transmission or front propeller shaft

*BA41.10-P-1001-01A

 Grease quantity

*BF41.10-P-1001-01A

8

Loosen fitted sleeves on flexible coupling.

AR41.10-P-0050-09DA



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

9

Detach flexible coupling from transmission (1)

 Installation: Check the flexible coupling, replace if necessary.

 Self-locking nut, flexible coupling to transmission or front propeller shaft

*BA41.10-P-1001-01A

10

Detach center shifter console and shift rod from transmission (1)

AR26.60-P-0600-02PI

11

Disconnect electrical connector from backup lamp switch

12

Separate hydraulic line (6) for clutch operating system

 Seal off lines to prevent the ingress of foreign bodies.

 Set of stop plugs

*129589009100

13

Remove bolts on starter

 Tie starter to one side with lines connected.

 Bolt connecting starter to crankcase

*BA15.30-P-1003-01N

14

Remove bolts (arrows) from transmission (1)

 Bolt, transmission to engine

*BA26.10-P-1001-01C

15

Remove transmission (1) downwards at an angle

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

Vehicle lift for major assemblies/scissors-type pallet forklift

gotis://A_01_07.1

Lashing strap as tilt control
gotis://H_00.1_05.2

16

Carry out visual inspection on transmission (1)

 Carry out visual inspection on central clutch release bearing, grooved ball bearing, thrust bearing and flywheel.

 Installation: Check for noises, rough running, leaks and wear, replace appropriate parts if necessary.

17

Install in the reverse order

18

Bleed clutch operating system

AR25.20-P-0070P

19

Perform basic programming

Model 203

AR00.19-P-0200P

Model 209

AR00.19-P-0200Q



Checking

20

Inspect transmission oil level

 Carry out measurement e.g. with a slanted Allen wrench. The correct oil level is 10 mm below the bottom edge of the filler opening.

 Oil drain screw to transmission

*BA26.40-P-1003-01C

 Oil filler plug to transmission

*BA26.40-P-1004-01C

 Transmission oil

*BF26.10-P-1001-01C

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

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

AS00.00-Z-0005-01A

21

Carry out engine test run and function check of clutch

Number

Designation

Transmission
716.6

BA26.10-P-1001-01C

Bolt, transmission to engine

Nm

40

Number

Designation

Trans-mission
716.6

BA26.40-P-1003-01C

Oil filler plug

Nm

35

BA26.40-P-1004-01C

Oil drain screw

Nm

30

Number

Designation

Engine
642

BA15.30-P-1003-01N

Bolt, starter to
cylinder crankcase

Nm

40

Number

Designation

Model
203

Model
209

BA41.10-P-1001-01A

Self-locking nut, flexible coupling to transmission or front propeller shaft

M10

Nm

40

40

M12

Nm

60

60

Number

Designation

Engine 642 in model 203, 209

BA49.10-P-1001-01V

Nut connecting front exhaust system to bracket

Nm

20

BA49.10-P-1002-01V

Bolt connecting bracket for front exhaust system to transmission

Nm

20

Number

Designation

Transmission
716.60/61/62/
630/631/632/
633/634/635/
636/638

Transmission
716.640/641/644/646/649, 716.653/654/655/656/657/658/66/67

BF26.10-P-1001-01C

Gear oil

Filling capacity

Liters

1.2

1.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-10A

BB00.40-P-0235-10A

Number

Designation

Model 203

Model 209

BF41.10-P-1001-01A

Grease quantity

Centering sleeve of propeller shaft

g

6

6

Specifications for Operating Fluids

Sheet

BB00.40-P-0267-00A

BB00.40-P-0267-00A