Remove/install pressure reservoir

AR26.60-D-0015A

Remove/install pressure reservoir

11.11.11

1.3.04

Removal and attachment of battery ground line on Model 203, 208, 209 taken away



Removing

1.1

Remove cover over right connector on transmission

Model 203, 208, 209

Model 901, 902, 903, 904 up to vehicle ident. end no. 159192

AR26.40-D-2002-03A

2.1

Disconnect electrical connector on hydraulic pump

Model 901, 902, 903, 904 up to vehicle ident. end no. 159192

Model 203, 208, 209

AR26.60-D-0007A

3.1

Remove exhaust bracket on exhaust

Model 203, 208, 209

 The exhaust bracket is located between transmission and exhaust.

4.1

Place transmission jack under transmission

Model 203, 208, 209

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

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

5.1

Remove rear engine mount

Model 208

AR22.10-P-1160HB

Model 203, 209

AR22.10-P-1160PR

6.1

Remove front propeller shaft from transmission

Model 203, 208, 209

 Flex disk remains on propeller shaft.

7.1

Lower transmission slightly

Model 203, 208, 209

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

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

8.1

Switch ignition on and shift through all gears until transmission is pressureless.

Model 901, 902, 903, 904 up to vehicle ident. end no. 159192

Model 203, 208, 209

 Use DAS to read out and check hydraulic pressure.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

8.2

Reduce hydraulic pressure using DAS.

Model 901, 902, 903, 904 as of vehicle ident. end no. 159193



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

9

Remove vent hose (2)

10

Remove pressure line (1) from pressure reservoir (9)

11

Rotate vent connection (3) approx. 45° clockwise and pull off

12

Unlock and unplug pressure sensor plug (5) sideways

13

Unscrew bolts (7) and remove clamp (6)

14

Undo bolt (8) and remove pressure reservoir (9).

 Danger!

Risk of injury caused by drilling gas-filled assemblies or components (noncombustible gases)

Wear safety glasses and a face mask.

AS00.00-Z-0006-01A

15.1

Dispose of pressure reservoir (9)

Only when installing new pressure reservoir (9).



Dispose of pressure reservoir

OS26.60-P-0015-01A



Install



Replace self-locking nuts and bolts

16

Position pressure reservoir (9) at screw on hand-tight with long bolt (8) at front

17

Insert vent connection (3) into pressure reservoir (9) and rotate approx. 45° counterclockwise

 Replace O-ring (4).

18

Use bolts (7) to screw on clamp (6) hand-tight

 Make sure that the grommet is fitted correctly.

19

Tighten screw (8)

 Model 901, 902, 903, 904

*BA26.40-N-1011-01A

19

Tighten screw (8)

 Model 203, 208, 209

*BA26.40-P-1011-01C

20

Tighten down clamp (6) with bolt (7)

 Model 901, 902, 903, 904

*BA26.40-N-1012-01A

20

Tighten down clamp (6) with bolt (7)

 Model 203, 208, 209

*BA26.40-P-1012-01C

21

Plug in pressure sensor plug (5)

22

Install vent hose (2)

 Bleed hose (2) must not be pinched off, take care in routing.

23

Bolt pressure line (1) tight



*BA26.60-N-1010-01A

24.1

Lift transmission up to installation position using lifting equipment

Model 203, 208, 209

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

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

25.1

Install front propeller shaft on transmission

Model 203, 208, 209



*BA41.10-P-1001-01A

26.1

Install rear engine mount

Model 208

AR22.10-P-1160HB

Model 203, 209

AR22.10-P-1160PR

27.1

Install exhaust bracket on exhaust

Model 203, 208, 209

 The exhaust bracket is located between transmission and exhaust.

28.1

Connect electrical connector to hydraulic pump

Model 901, 902, 903, 904 up to vehicle ident. end no. 159192

Model 203, 208, 209

AR26.60-D-0007A

29.1

Install right connector cover on transmission

Model 901, 902, 903, 904 up to vehicle ident. end no. 159192

AR26.40-D-2002-03A

Model 203, 208, 209:

 When installing cover, insert lug at the top.

30

Check, correct the hydraulic fluid level

AR26.60-D-0009A

Number

Designation

Trans-mission
716.643

BA26.40-N-1011-01A

Bolt of pressure reservoir to transmission housing

Nm

15

BA26.40-N-1012-01A

Clamp of pressure reservoir to transmission housing

Nm

15

Number

Designation

Trans-mission
716.6

BA26.40-P-1011-01C

Bolt of pressure reservoir to transmission housing

Nm

15

BA26.40-P-1012-01C

Clamp of pressure reservoir to transmission housing

Nm

15

Number

Designation

Trans-mission 716.622/
662

Trans-mission 716.643

Trans-mission 716.623

BA26.60-N-1010-01A

Pressure line, hydraulic unit to pressure reservoir

Nm

16

16

16

Number

Designation

Model
203

Model
208

Model
209

BA41.10-P-1001-01A

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

M10

Nm

40

40

40

M12

Nm

60

60

60