Disassemble/assemble transmission housing

AR26.40-D-2002B

Disassemble/assemble transmission housing

8.9.08

5.9.03

Repair method has been revised

Operation step 5, 6

AR26.50-D-4000-01B

5.9.03

Safety note for lifting platform, added

5.9.03

Safety note for hydraulic fluid, added



Removing

 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 injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A



Transmission up to transmission end no. 1037037:

Replace transmission

1

Detach cover of electrical connector on right of transmission

AR26.40-D-2002-03A

2.1

Unplug hydraulic pump connector

Up to vehicle ident. end no. 159192

AR26.60-D-0007A

3.1

Switch on ignition and switch through the gears until the transmission is unpressurized

Up to vehicle ident. end no. 159192

 Read out hydraulic pressure with STAR DIAGNOSIS The transmission must be unpressurized.

3.2

Read out hydraulic pressure with STAR DIAGNOSIS

As of vehicle ident. end no. 159193

4

Drain hydraulic fluid

AR26.60-D-0008-01A



Clean

5

Clean the area around the oil drain screw (8)

Cleaner from package

*BR00.45-Z-1032-04A

6

Remove oil drain screw (8) and drain transmission oil

7

Remove transmission

AR26.10-D-0020E



Disassemble

8

Remove guide pins (10)

9

Mount transmission on assembly device

AR26.10-P-0036D

10

Remove output flange (2)

 Pin wrench

*901589000700

11

Remove pressure reservoir

AR26.60-D-0015A

12

Remove rpm sensor

AR26.19-D-0023A

13

Remove hydraulic pump

AR26.60-D-0007A

14.1

Remove turning angle sensors

Up to vehicle ident. end no. 159192

AR26.19-D-0022A

15

Remove sensor plate

Up to vehicle ident. end no. 159192

AR26.60-D-0017A

As of vehicle ident. end no. 159193

AR26.60-D-0017B

16

Removing hydraulic module

AR26.60-D-0019A

17

Remove oil reservoir

AR26.60-D-0020A

18

Remove vent hose (6)

19

Remove bleed connection (9)

20

Remove vent housing (4)

21

Remove reverse gear detent (3)

 Extraction claw

*716589033300

22

Remove wiring harness (11)

 Remove screw (12) and expose electrical wiring harness (11).

23

Remove bracket (14)

Up to vehicle ident. end no. 159192

24

Remove central clutch release bearing

AR26.40-D-0345A

25

Disassemble transmission housing

Up to vehicle ident. end no. 159192

AR26.40-D-2002-01A

As of vehicle ident. end no. 159193

AR26.40-D-2002-01B

 Retainer wrench

*716589000900

 Drift

*711589041500

Circlip pliers for external circlip

26

Remove main shaft and countershaft with shift unit

Up to vehicle ident. end no. 159192

AR26.50-D-4000-01A

As of vehicle ident. end no. 159193

AR26.50-D-4000-01B

 Assembly plate

*716589003100

 Assembly plate

*210589013100

 Puller

*000589653300

 Jaw

*000589873300

 Bracket set

*716589004000



Assemble

27

Install main shaft and countershaft with shift unit

Up to vehicle ident. end no. 159192

AR26.50-D-4000-02A

As of vehicle ident. end no. 159193

AR26.50-D-4000-02B

 Insertion sleeves

*716589003300

28

Assemble transmission housing

Up to vehicle ident. end no. 159192

AR26.40-D-2002-02A

As of vehicle ident. end no. 159193

AR26.40-D-2002-02B

 Bolt, front section of transmission housing to rear section of transmission housing

*BA26.40-N-1008-01A

 Collar nut, output flange to main shaft

*BA26.50-N-1005-01D

 Countershaft bolt

*BA26.50-N-1005-01D

 Insertion tool

*716589043300

 Drift

*210589031500

 Pin wrench

*901589000700

 Drift

*716589011500

 Drift

*210589041500

 SEQ gearshift lever

*000589856300

Sealant

*BR00.45-Z-1017-01A

29

Install hydraulic pump

AR26.60-D-0007A

30.1

Install bracket (14)

Up to vehicle ident. end no. 159192



*BA26.60-N-1023-01A

31

Mount electrical wiring harness (11)

 Tighten screw (12) and route electrical wiring harness (11).



*BA26.60-N-1020-01A

32

Drive in reverse gear catch (3) up to the stop

33

Install bleed connection (9)

 The side with the flat on must point towards the grooved drive stud.

34

Install vent housing (4)

 Grease contact surfaces of transmission housing.



*BA26.60-N-1018-01A

35

Install vent hose (6)

36

Install central clutch release bearing

AR26.40-D-0345A

37

Install oil reservoir

AR26.60-D-0020A

38

Install hydraulic unit

AR26.60-D-0019A

39

Install sensor plate

Up to vehicle ident. end no. 159192

AR26.60-D-0017A

As of vehicle ident. end no. 159193

AR26.60-D-0017B

40.1

Install turning angle sensors

Up to vehicle ident. end no. 159192

AR26.19-D-0022A

41

Install rpm sensor

AR26.19-D-0023A

42

Tighten oil drain screw (8)



*BA26.40-N-1001-01A

43

Remove oil filler screw (7)

44

Fill with transmission oil

 The transmission must be in the installation position.

 Correct oil level = 10 mm below bottom edge of filler opening.

*BF26.00-N-1001-01G

 Carry out measurement e.g. with a slanted Allen wrench.



Filling capacity of transmission oil revised

BT26.00-P-0001-01A

45

Tighten oil filler screw (7)



*BA26.40-N-1002-01A

46

Install pressure reservoir

AR26.60-D-0015A

47

Remove transmission from assembly device

AR26.10-P-0036D

48

Install guide pins (10)

 Hammer guide pins (10) approx. 10 mm into the front section of the transmission housing.



Install

49

Install transmission

AR26.10-D-0020E

50

Top up hydraulic oil

AR26.60-D-0008-01A



*BF26.00-N-1002-01G

 Hand pump

*210589007100

51

Teach in gears with STAR DIAGNOSIS

Number

Designation

Trans-mission
716.643

BA26.40-N-1001-01A

Oil drain plug

Nm

60

BA26.40-N-1002-01A

Oil filler plug

Nm

50

BA26.40-N-1008-01A

Bolt for front section of transmission housing to rear section of transmission housing

Nm

28

Number

Designation

Trans-mission
716.6

BA26.50-N-1001-01D

Nut, output flange to main shaft

M121.5

Nm

110

M241.5

Stage 1

Nm

-

Stage 2

Nm

-

Stage 3

Nm

-

M261.5

Stage 1

Nm

-

Stage 2

Nm

-

Stage 3

Nm

-

BA26.50-N-1005-01D

Bolt, countershaft to countershaft bearing

M141.5

Nm

75

M181.5

Nm

100

Number

Designation

Trans-mission 716.643

BA26.60-N-1018-01A

Bolt, vent housing to transmission

Nm

6.0

BA26.60-N-1020-01A

Ground terminal point, wiring harness to transmission

Nm

10

BA26.60-N-1023-01A

Bracket, connector of turning angle sensors

Nm

10

Number

Designation

Transmission
716.643

BF26.00-N-1001-01G

Gear oil

Filling capacity

Liters

1.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-10A

BF26.00-N-1002-01G

Hydraulic oil

Filling capacity

Liters

0,5

Specifications for Operating Fluids

Sheet

BB00.40-P-0345-00A

Number

Designation

Order number

BR00.45-Z-1032-04A

Cleaner from package

Würth GmbH
D-74650 Künzelsau

BR00.45-Z-1017-01A

Loctite 5203 sealant

002 989 71 20 10