Remove/install transmission

AR26.10-B-0020DT

Remove/install transmission

07.11.2019

Transmission

712.820/830 in model 963

1

Gearbox

5

Oil piping

2

Engine

6

Bolt

3

Bolt

Y900

Transmission actuator

4

Ground strap holder

100

Clutch protective valve

Y900

Transmission actuator

 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

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Notes on evaluating hydraulic hoses

AH55.30-N-0001-01A



Remove

1

Park the vehicle on a flat surface, stop the ignition, and apply the parking brake

 Shim the vehicle wheels to prevent unintentional movements.

2

Turn off the main switch of the vehicle

3

Tilt the cab

 Cable set

*970589003100

4

Remove the vehicle chassis running board

5

Disconnect battery ground cable

6

Remove the ground strap holder (4) with the engine ground strap (2)

7

Remove the propeller shaft from the transmission (1)

 Tie the propeller shaft to the vehicle chassis. Be careful not to damage the propeller shaft and peripheral components in the vehicle chassis.

 Mark the coupling flange with the propeller shaft so that it is installed in the same position.

8

Remove the transmission control unit electrical connector (TCM)

9

Remove the speed sensor electrical connector

10

Depressurize the vehicle compressed-air system

11

Remove the compressed-air feed line on the transmission actuator (Y900)

 Be careful as there may be residual pressure.

12

Remove the clutch protective valve (100) on the transmission actuator (Y900)

13

Remove the power take-off connectors

 Only on vehicles with power take-off.

14

Remove the propeller shaft from the power take-off

 Only on vehicles with power take-off NA 121 1b.

15

Remove hydraulic pump on the power take-off

 Only on vehicles with power take-off NA 131 2c.

 Be careful of oil that will come out of the power take-off. Collect the oil in an appropriate container and dispose of it in Eco-friendly manner.

16

Separate transmission (1) cooling oil line (5) connections

 Take care not to damage the connections. Use the closing plugs to avoid oil leakage.

 Plug

*963589019100

17

Support the transmission (1) on a suitable crane

18

Remove the transmission mount screws (6)

19

Support the engine (2) with a suitable crane and support underneath with a hydraulic jack and shims

20

Remove the bolts (3) attaching the transmission to the engine

21

Lift the transmission (1)

 You will need to move the transmission (1) backwards to remove the drive shaft. Be careful when moving the transmission (1).



Clean

22

Clean the gearbox (1) and its components



Check

23

Check the transmission (1) and its components for damages, cracks and leaks

AR26.10-B-0005DT

AR26.10-B-0010DT



Install

24

Lift the transmission (1) using a suitable crane

 Be careful when moving the transmission (1).

25

Fit the drive shaft into the clutch assembly

 Correctly align the transmission (1) with engine (2) and cushion on vehicle chassis. Use pliers to turn the drive shaft.

 Pliers

*715589013700

26

Install the bolts (3) attaching the transmission (1) to the engine (2)

  Screw of the transmission on the engine

*BA25.10-B-1005-01DT

27

Install the bolts (6) attaching the transmission (1) to the cushion

  Transmission bolt on the bearing

*BA25.10-B-1002-01DT

28

Install the propeller shaft on the coupling flange of the transmission (1)

  Coupling flange bolt with propeller shaft

*BA25.10-B-1003-01DT

29

Install the clutch protective valve (100) on the transmission actuator (Y900)

30

Install the compressed-air line on the transmission actuator (Y900)

31

Install the speed sensor electrical connector

32

Install the transmission control unit electrical connector (TCM)

33

Install the ground strap holder (4) with the engine ground strap (2)

34

Connect the transmission (1) cooling oil line (5)

35

Install the power take-off connectors

 Only on vehicles with power take-off.

36

Install hydraulic pump on the power take-off

 Only on vehicles with power take-off NA 131 2c.

37

Install the power take-off propeller shaft

 Only on vehicles with power take-off NA 121 1b.

  Propeller shaft bolt on the power take-off

*BA25.10-B-1004-01DT

38

Connect battery mass cable

39

Installing the running board on the vehicle chassis

40

Turn on the main switch of the vehicle

41

Tilt the cab



Check

42

Check transmission oil level (1)



AP26.00-B-2601MB

 Filling volume

*BF26.10-B-1002-01DT

Learning

43

Connect the diagnosis equipment, start the XENTRY, and turn the ignition on

 Only when any transmission components (1) such as: pneumatic central clutch actuator, transmission control unit or speed sensor have been replaced.

44

Carry out the procedure "Commissioning" on the tab "Retrofitting"

 Through the option "Diagnosis"  "TCM - Transmission actuation (A5)

45

Finish the XENTRY and disconnect the diagnosis equipment

 On the first kilometers, some noises and leaps may occur during gear shifting related to the self-adjustment process carried out by the transmission (1).

 G291 - G340

Number

Designation

Vehicle 963 with transmission 712.820/830

BA25.10-B-1002-01DT

Transmission bolt on the bearing

Nm

350

 G291 - G340

Number

Designation

Vehicle 963 with transmission 712.820/830

BA25.10-B-1003-01DT

Coupling flange bolt with propeller shaft

M12

Nm

100

M14

Nm

154

 G291 - G340

Number

Designation

Vehicle 963 with transmission 712.820/830

BA25.10-B-1004-01DT

Propeller shaft bolt on the power take-off

M8

Nm

25

M10

Nm

60

M12

Nm

100

 G291 - G340

Number

Designation

Vehicle 963 with transmission 712.820/830

BA25.10-B-1005-01DT

Screw of the transmission on the engine

Nm

50

 G291-G340

Number

Designation

Gearbox 712.820/830 in the vehicle 963

BF26.10-B-1002-01DT

Filling volume

Transmission with retarder

Litro

9,4

Transmission without retarder

Litro

9,2

Oil class

Consultar documento BB00.40-B-0235-16A no site Mercedes-Benz / Guia de Lubrificantes