Remove/install transmission

AR26.10-Y-0020A

Remove/install transmission

30.10.2019

Transmission

400.713 in model 831.247

Transmission removal and installation procedure

6

Neutral position sensor 12S01

8

Reverse gear sensor 12S02

9

Rotational speed sensor 60B02

135

Cable tie

136

Countershaft sensor 60B03

159

Clutch booster

137

Shift cable

138

Shift cable lock

139

Selector cable

140

Select cable lock

141

Selector cable mounting bracket

142

Gear select bracket

143

Exhaust pipe

144

Bottle jack

145

Transmission bottom mounting bolts

146

Special tool removal assembly 090 589 03 62 00

147

Special tool assembly stand 090 589 01 99 00

147

Assembly stand 090 589 01 99 00

148

Transmission support arm

149

Transmission mounting bolts

150

Flywheel housing

 

Remove/install

 Danger

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

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

AS00.00-Z-0010-01A

 Caution

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

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

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

1

Remove propeller shaft from transmission.

AR41.10-Y-0050A

2

Remove the front axle.

AR33.10-Y-0100A

3

Remove the wiring harness cable tie (135).

4

Disconnect electrical connectors of the rotational speed sensor 60B02 (9), reverse gear sensor 12S02 (8) and neutral position sensor 12S01 (6) counter shaft sensor 60B03 (136) from the transmission.

5

Remove clutch booster (159) from the transmission.

 This is not necessary to remove pneumatic and hydraulic hoses from clutch booster for its removal.

 Clutch booster to the transmission

*BA26.10-Y-1040-01A

6

Remove the shift cable (137) and shift cable lock (138).

 Shift cable

*BA26.10-Y-1039-01A

7

Remove the selector cable (139) and the select cable lock (140).

 Selector cable

*BA26.10-Y-1038-01A

8

Remove shift and selector cable mounting bracket (141) from transmission.

 Shift and selector cable mounting bracket to the transmission

*BA26.10-Y-1037-01A

9

Remove gear select bracket (142) from gearbox.

 Gear select bracket to the gearbox

*BA26.10-Y-1036-01A

10

Remove the exhaust pipe (143) from turbocharger.

 Exhaust pipe to the turbocharger

*BA26.10-Y-1035-01A

11

Remove transmission bottom mounting bolts (145).


Support the engine using a bottle jack (144) and wooden block. Support the engine on the clutch housing area and not on the oil pan.
Engine mounting brackets are damaged because of the engine is not supported properly.

 Use wooden block between the jack and engine to avoid metal to metal contact.

12

Support transmission from bottom with special tool removal assembly (146) and assembly stand (147).

 Assembly stand

*090589019900

 Removal assembly

*090589036200

13

Remove transmission support arm (148) by removing the bolts from left hand side and right hand side of the transmission unit.

 left hand side and right hand side supporting arms

*BA26.10-Y-1034-01A

14

Remove transmission mounting bolts (149) from flywheel housing (150).

 Transmission unit to the flywheel housing

*BA26.10-Y-1033-01A

15

Pull out transmission unit from the flywheel housing by suitably adjusting the special tool assembly stand (147) height.

 Installation: Raise the special tool assembly stand (147) and move it towards the engine in order to align the transmission input shaft into the clutch assembly.

 Assembly stand

*090589019900

16

Install in the reverse order.

 G85 Transmission

Number

Designation

Transmission 400.710 in model 400.204/207/212/216/231
Transmission 400.713 in model 831.247

BA26.10-Y-1033-01A

Transmission unit to the flywheel housing

Nm

405.5

 G85 Transmission

Number

Designation

Transmission 400.710 in model 400.204/207/212/216/231
Transmission 400.713 in model 831.247

BA26.10-Y-1034-01A

left hand side and right hand side supporting arms

Nm

16012

 G85 Transmission

Number

Designation

Transmission 400.710 in model 400.204/207/212/216/231
Transmission 400.713 in model 831.247

BA26.10-Y-1035-01A

Exhaust pipe to the turbocharger

Nm

15012

 G85 Transmission

Number

Designation

Transmission 400.710 in model 400.204/207/212/216/231
Transmission 400.713 in model 831.247

BA26.10-Y-1036-01A

Gear select bracket to the gearbox

Nm

231

 G85 Transmission

Number

Designation

Transmission 400.710 in model 400.204/207/212/216/231
Transmission 400.713 in model 831.247

BA26.10-Y-1037-01A

Shift and selector cable mounting bracket to the transmission

Nm

231.8

 G85 Transmission

Number

Designation

Transmission 400.710 in model 400.204/207/212/216/231
Transmission 400.713 in model 831.247

BA26.10-Y-1038-01A

Selector cable

Nm

20(+0, -2)

 G85 Transmission

Number

Designation

Transmission 400.710 in model 400.204/207/212/216/231
Transmission 400.713 in model 831.247

BA26.10-Y-1039-01A

Shift cable

Nm

408.8

 G85 Transmission

Number

Designation

Transmission 400.710 in model 400.204/207/212/216/231
Transmission 400.713 in model 831.247

BA26.10-Y-1040-01A

Clutch booster to the transmission

Nm

18