Remove/install transmission

AR26.10-S-0020CB

Remove/install transmission

08.02.2019

Model

415 with transmission 700.720

Modification notes

12.10.2018

Work procedure changed and method extended

Operation steps 1 to 54

01.02.2019

Work procedure revised

Operation steps 1, 2, 4,

AR26.60-S-6626-01CA

01.02.2019

Method extended

Operation step 24

01.02.2019

Basic data reference added

Operation step 52

Shown with engine 607

1

Transmission

2

Shift cables

3

Screw

4

Screw

5

Vent line

6

Hydraulic line

7

Safety clip

8

Electrical connector

Shown with engine 607

1

Transmission

9

Bolts

10

Stud bolt

 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 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

 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

Topical note

Brake fluid notes

AH42.50-P-0001-01A



Remove

1

Jack up vehicle.

AR00.60-S-1000C

 Do not lift vehicle yet.

2

Remove fuel injection system control unit.

AR07.08-S-7008CD

3

Unhook shift cables (2).

AR26.60-S-6626-01CA

 Unhook shift cables (2) from ball heads only.

4

Remove front axle carrier.

AR33.10-S-0001C

5

Remove front crossmember.

Model 415.7

AR31.30-S-4115C

6

Remove front axle shafts.

AR33.30-S-6530C

7

Remove crankshaft position sensor.

Model 415 with engine 607

AR15.12-S-2133CD

Model 415 with engine 608

AR07.04-S-0059CE

MODEL 415 with ENGINE 200

AR15.12-S-2133CB

8

Remove shift cables (2) from holders.

AR26.60-S-6626-01CA

9

Remove bolt (3) .

10

Remove bolt (4) from ground line.

11

Remove coolant preheater from transmission (1).

Model 415 with engine 607

AR20.00-S-0003CD

 Do not drain off coolant. Do not detach coolant hoses.

12

Remove starter from transmission housing.

Model 415 with engine 607

AR15.30-S-7100CD

Model 415 with engine 608

AR15.30-S-7100CE

MODEL 415 with ENGINE 200

AR15.30-S-7100CB

 Do not remove electrical lines. The starter remains in the vehicle.

13

Mount engine support fixture.

AR26.10-S-0006-01C

 Engine bracket

*415589016200

 Engine bracket

*415589026200

14

Remove air filter housing.

AR09.10-S-1150CD

15

Remove bleed line (5).

 To do so, unclip bleed line (5) from holder and detach from transmission (1).

16

Disconnect hydraulic line (6).

 To do so, unclip hydraulic line (6) from holder and lift up safety clip (7). Seal the connections and collect the discharged brake fluid.

 Record plug

*129589009100

17

Detach electrical connector (8) from backup light switch.

18

Remove left engine carrier.

AR22.10-S-4350CD

19

Remove upper bolt of transmission (1) from crankcase.

20

Raise vehicle.

21

Lower engine using engine support fixture.


Lower engine only far enough to gain access to the transmission (1).
Otherwise damage may occur to the right engine mount.

 Engine bracket

*415589016200

 Engine bracket

*415589026200

22

Support the transmission (1).



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

23

Remove screws (9).

24

Unscrew nut of stud bolt (10).

25

Remove stud bolt (10).

26

Remove transmission (1).

 Aid of helper required.



Check

27

Check central clutch release bearing for wear and leak tightness.

If corresponding findings are present,



replace central clutch release bearing.

AR25.20-S-0180C



Install

28

Install the transmission (1).



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

 Aid of helper required.
Apply light coating of grease to main shaft.

Long-life grease

*BR00.45-Z-1001-06A

29

Screw in stud bolt (10).

 Stud bolt in transmission housing

*BA26.10-N-1003-01J

30

Screw on nut of stud bolt (10).

 Nut, transmission to crankcase

*BA26.10-N-1002-01J

31

Screw in screws (9).

 Bolt, transmission to crankcase/oil pan

*BA26.10-N-1001-01J

32

Remove major assembly mount and support plate.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

33

Lower vehicle.

34

Screw in upper bolt of transmission (1) on crankcase.

 Bolt, transmission to crankcase/oil pan

*BA26.10-N-1001-01J

35

Install left engine carrier.

AR22.10-S-4350CD

36

Connect hydraulic line (6).

37

Install bleed line (5).

38

Connect electrical connector (8) of backup light switch.

39

Bleed clutch actuation system.

AR25.20-S-0070C

40

Install air filter housing.

AR09.10-S-1150CD

 Do not yet install engine compartment lining at bottom and front fender liner.

41

Remove engine support fixture.

AR26.10-S-0006-01C

 Engine bracket

*415589016200

 Engine bracket

*415589026200

42

Install starter into transmission housing.

Model 415 with engine 607

AR15.30-S-7100CD

Model 415 with engine 608

AR15.30-S-7100CE

MODEL 415 with ENGINE 200

AR15.30-S-7100CB

43

Mount coolant preheater onto transmission (1).

Model 415 with engine 607

AR20.00-S-0003CD

44

Screw in bolt (3).

 Bolt, transmission to crankcase/oil pan

*BA26.10-N-1001-01J

45

Attach ground line.

 Screw in bolt (4) to do this.

 Bolt, ground line to transmission

*BA26.40-N-1002-01F

46

Install shift cables (2) into holder.

AR26.60-S-6626-01CA

47

Install crankshaft position sensor.

Model 415 with engine 607

AR15.12-S-2133CD

Model 415 with engine 608

AR07.04-S-0059CE

MODEL 415 with ENGINE 200

AR15.12-S-2133CB

48

Replace radial shaft sealing rings of front axle shafts on transmission (1).

AR26.40-S-0339C

49

Install front axle shaft.

AR33.30-S-6530C

50

Install front axle carrier.

AR33.10-S-0001C

51

Install front crossmember.

Model 415.7

AR31.30-S-4115C

52

Mount shift cables (2) onto ball heads.

AR26.60-S-6626-01CA

 Model 415 with engine 607Bolt/nut, bracket for flexible tube to transmission

*BA49.10-N-1006-01Q



Check

53

Check clutch and gearshift system for proper operation.

If the transmission (1) does not shift easily through the gears,



Adjust shift cables (2).

AR26.60-S-6633CA

54

Install fuel injection system control unit.

AR07.08-S-7008CD



Check

55

Check transmission oil level.

If corresponding findings are present,



rectify transmission oil level.

Drain/fill transmission oil

AR26.00-S-0200C

 Manual transmission, complete

Number

Designation

Transmission 700.720 in model 415

BA26.10-N-1001-01J

Bolt, transmission to crankcase/oil pan

Nm

44

 Manual transmission, complete

Number

Designation

Transmission 700.720 in model 415

BA26.10-N-1002-01J

Nut, transmission to crankcase

Nm

44

 Manual transmission, complete

Number

Designation

Transmission 700.720 in model 415

BA26.10-N-1003-01J

Stud bolt in transmission housing

Nm

7

 Housing

Number

Designation

Transmission 700.720 in model 415

BA26.40-N-1002-01F

Bolt, ground line to transmission

Nm

21

 Exhaust system

Number

Designation

Engine 607 in model 415

BA49.10-N-1006-01Q

Bolt/nut, bracket for flexible tube to transmission

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11