Remove/install transmission

AR26.10-D-0020R

Remove/install transmission

14.02.2020

Transmission

711.680/683 in model 909

Modification notes

08.01.2020

Bolt, speed sensor for tachograph to transmission

Transmission 711.680/683/685

BA26.19-N-1001-01I

12.02.2020

Gear oil

Transmission 711.68 (except 711.683) in model 909 Transmission 711.68 (except 711.685) in model 907

BF26.00-N-1001-01A

Shown on model 909.843

1

Transmission

10

Engine cross member

5

Propeller shaft

11

Engine mount

6

Hydraulic hose

G3

Tachograph travel distance and speed sensor

7

Hydraulic line

S19

Backup lamp switch

8

Bracket

Shown on vehicle with code MS9(Engine version EURO 4)

1

Transmission

13

Bracket

12

Bracket

14

Bracket

Shown on vehicle with code MP5 (Engine version Euro 5)

1

Transmission

12

Bracket

14

Bracket

1

Transmission

2

Support plate

3

Major assembly mount

4

Oil filler plug

 Danger

Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC.

No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

 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

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Brake fluid notes

AH42.50-P-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



Remove

1

Disconnect ground line from battery.

2

Extract brake fluid from brake fluid reservoir.

3

Raise vehicle and fix in place on vehicle lift.

AR00.60-D-0100F

4

Drain fluid from transmission.

If the transmission (1) is replaced or repair work is conducted on the transmission (1).



AP26.00-D-2601R

5.1

Secure propeller shaft (5) in area of transmission (1) and propeller shaft intermediate bearing against falling down.

Transmission 711.680/683 in model 909
with code IR5 (Wheelbase 4025 mm)

5.2

Secure propeller shaft (5) in area of transmission (1) and propeller shaft intermediate bearing against falling down.

Transmission 711.680/683 in model 909
with code IR3 (Wheelbase 3550 mm)

6.1

Remove propeller shaft intermediate bearings.

Transmission 711.680/683 in model 909
with code IR5 (Wheelbase 4025 mm)

6.2

Remove propeller shaft intermediate bearing.

Transmission 711.680/683 in model 909
with code IR3 (Wheelbase 3550 mm)

7

Remove check strap of propeller shaft (5).

8

Remove propeller shaft (5) from transmission (1) and attach at side to substructure.

AR41.10-D-0050R

9

Remove shift cables from transmission (1).

AR26.60-D-6626-01R

Long-life grease

*BR00.45-Z-1001-06A

10

Release and disconnect electrical connector from backup light switch (S19).

11

Detach tachograph travel distance and speed sensor (G3) from transmission (1) and fasten to side of substructure.

Transmission 711.680/683 in model 909
with code IT6 (4.6-tonner)
with code JV6 (Tachograph pre-installation kit)

12

Pull out safety clip at separation point (arrow) of clutch operation.

13

Remove hydraulic hose (6) from hydraulic line (7).

14

Seal connections with suitable stop plugs.

 Record plug

*129589009100

15

Remove holder (8).

16

Remove bracket (12).

Transmission 711.680 in model 909
with code MP5 (Engine version Euro 5)

17

Position major assembly mount (3) with support plate (2) on 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

18

Secure transmission (1) using suitable means to support plate (2).

19

Use suitable means to prop up engine between oil pan and front axle carrier.

20

Remove engine crossmember (10) together with engine mount (11).

AR22.10-D-1170R

21

Remove holder (14) and place to one side.

22

Remove holder (13).

Transmission 711.683 in model 909
with code MS9 (Engine version Euro 4)

23

Remove remaining bolts of transmission (1) on engine.

 Note different lengths of bolts, mark installation locations if necessary.

24

Remove transmission (1) from engine, move out to the rear and lower.



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Aid of helper required.



Check

25

Perform visual check on central clutch release bearing.

Notes on working on central clutch release bearing of transmission

AH26.40-N-1001-01S

If a problem is detected,



replace central clutch release bearing.

AR25.20-D-0180R

26

Check intermediate rubber layer on holder (8).

If wear or damage is detected,



install new holder (8).



Install

27

Move transmission (1) forward and position on engine.



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Aid of helper required.

28

Tighten two bolts on opposite sides of transmission (1) lightly by hand.

29

Mount holder (14).

 Screw/bolt, manual transmission to engine

*BA26.10-N-1001-01A

30

Install holder (12).

Transmission 711.680 in model 909
with code MP5 (Engine version Euro 5)

 Nut/bolt, bracket to front exhaust system

*BA49.10-N-1003-01I

 Screw/bolt, manual transmission to engine

*BA26.10-N-1001-01A

31

Install holder (13).

Transmission 711.683 in model 909
with code MS9 (Engine version Euro 4)

 Screw/bolt, manual transmission to engine

*BA26.10-N-1001-01A

32

Tighten remaining bolts of transmission (1).

 Screw/bolt, manual transmission to engine

*BA26.10-N-1001-01A

33

Install engine crossmember (10) together with engine mount (11).

AR22.10-D-1170R

34

Remove support between oil pan and front axle carrier.

35

Release transmission (1) from support plate (2) and move out major assembly mount (3).



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

36

Install holder (8).

 Nut, bracket to catalytic converter

*BA14.40-N-1006-02D

 Bolt, exhaust bracket to transmission and exhaust

*BA26.40-N-1019-01A

37

Remove stop plugs.

 Record plug

*129589009100

38

Check sealing ring of hydraulic line (7).

If damage is detected on the sealing ring of the hydraulic line (7),



replace hydraulic line (7).

 M61

*BA00.10-N-1002-04A

39

Connect hydraulic hose (6) to hydraulic line (7).

40

Attach safety clip of separation point (arrow).

41

Check sealing ring of tachograph travel and speed sensor (G3).

Transmission 711.680/683 in model 909
with code IT6 (4.6-tonner)
with code JV6 (Tachograph pre-installation kit)

If damage is detected on the sealing ring of the tachograph travel and speed sensor (G3),



replace sealing ring of the tachograph travel and speed sensor (G3).

42

Mount tachograph travel distance and speed sensor (G3) to transmission (1).

Transmission 711.680/683 in model 909
with code IT6 (4.6-tonner)
with code JV6 (Tachograph pre-installation kit)

 Transmission 711.680/683 in model 909
with code IT6 (4.6-tonner)
with code JV6 (Tachograph pre-installation kit)Bolt, speed sensor for tachograph to transmission

*BA26.19-N-1001-01I

43

Connect electrical connector to backup lamp switch (S19).

44

Mount shift cables onto transmission (1).

AR26.60-D-6626-01R

Long-life grease

*BR00.45-Z-1001-06A

45

Mount propeller shaft (5) onto transmission (1).

AR41.10-D-0050R

46

Install check strap of propeller shaft (5).

 Bolt, retaining bracket to frame floor assembly

*BA41.10-N-1004-01B

47.1

Mount propeller shaft intermediate bearings.

Transmission 711.680/683 in model 909
with code IR5 (Wheelbase 4025 mm)

 Screw/bolt, propeller shaft center support bearing to frame floor assembly

BA41.40-N-1001-01A

47.2

Mount propeller shaft intermediate bearing.

Transmission 711.680/683 in model 909
with code IR3 (Wheelbase 3550 mm)

 Screw/bolt, propeller shaft center support bearing to frame floor assembly

BA41.40-N-1001-01A

48

Remove attached retainer for preventing propeller shaft (5) from dropping down.



Check

49

Fill transmission with oil.

If the transmission (1) is replaced or repair work is conducted on the transmission (1).



AP26.00-D-2601R

50

Correct brake fluid level in brake fluid reservoir.

51

Connect ground line to battery.

52

Bleed clutch operating system.

AR25.20-D-0070R

53

Unscrew oil filler screw (4), check transmission oil level and correct if necessary.

 The automatic transmission fluid must be level with the filler hole.

 Transmission 711.680 in model 909
Transmission 711.683 in model 909Gear oil

*BF26.00-N-1001-01A

 Filling screw

*BA26.40-N-1002-01A

54

Check coupling for proper operation.

55

Check gearshift system and shift cables for ease of movement.

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



adjust shift cables.

AR26.60-D-6633R

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-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

56

Perform engine test run and check transmission (1) for leak tightness and proper operation.

57

Lower vehicle and release from vehicle lift.

AR00.60-D-0100F

 Metric bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-N-1002-04A

M61

Nm

9

13

 Exhaust aftertreatment

Number

Designation

Engine 646 in model 906, 909

BA14.40-N-1006-02D

Nut, bracket to catalytic converter

Nm

23

 Manual transmission, complete

Number

Designation

Transmission 711.680

Transmission 711.683

BA26.10-N-1001-01A

Screw/bolt, manual transmission to engine

Nm

38

38

 Sensors

Number

Designation

Transmission 711.680/683/685

BA26.19-N-1001-01I

Bolt, speed sensor for tachograph to transmission

Nm

4

 Transmission housing

Number

Designation

Transmission 711.680

Transmission 711.683 in model 909

BA26.40-N-1002-01A

Filling screw

Nm

34

50

 Transmission housing

Number

Designation

Transmission 711.680

Transmission 711.683 in model 909

BA26.40-N-1019-01A

Bolt, exhaust bracket to transmission and exhaust

Nm

23

23

 Propeller shaft

Number

Designation

Model 909

BA41.10-N-1004-01B

Bolt, retaining bracket to frame floor assembly

M121.5

Nm

100

 Exhaust system

Number

Designation

Engine 646.7 in model 909

BA49.10-N-1003-01I

Nut/bolt, bracket to front exhaust system

Nm

23

 Manual transmission

Number

Designation

Transmission 711.68 (except 711.683) in model 909
Transmission 711.68 (except 711.685) in model 907

Transmission 711.683 in model 909

BF26.00-N-1001-01A

Gear oil

Filling capacity

Liter

2,1

2,1

with PTO

Liter

2,6

–

with additional drive system

Liter

–

–

Sheet

BB00.40-P-0235-10A

BB00.40-P-0235-10A

Sheet

-

-

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11