Remove/install transmission

AR26.10-S-0020SD

Remove/install transmission

24.8.15

Transmission

716.6 in model 636, 639

Shown on vehicle as from vehicle identification number (VIN) 060147 and with CODE ZG2 (Permanent all-wheel drive)

1

Bracket

2

Bolt

3

Hydraulic line

4

Securing clamp

9

Propeller shaft

Shown on vehicle up to VIN 060146

3

Hydraulic line

4

Securing clamp

5

Shift cable

6

Ball socket

7

Bracket

8

Locking plate

9

Propeller shaft

10

Bracket

11

Nut

12

Bolt

13

Ground cable

14

Bolt

15

Bolt

Shown on vehicle with CODE J19 (1 day/2 driver tachograph)

B6/4

Speed inductive sensor

 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

 Danger !

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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 

Remove/install

 Danger !

Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

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

AS54.10-Z-0001-01A

1

Disconnect ground line from battery

AR54.10-S-0003S



Notes on battery

AH54.10-P-0001-01A

2

Remove rear lower engine compartment paneling

MODEL 636, 639.7##/8## ## as of 055347

AR61.20-S-1105-03S

3

Remove bracket (1)

Model 636, 639.### ## as of 060147 with transmission 716.6

 Unscrew bolt (2) to do this.

4

Detach hydraulic line (3)



Brake fluid notes

AH42.50-P-0001-01A

 To do so, remove the safety clamp (4). Seal the connections and collect the discharged brake fluid.

 Record plug

*129589009100

5

Install transmission support fixture

AR01.10-S-2400-04S

 The transmission support must rest against the oil pan.

6.1

Remove engine cross member at rear

Model 636, 639 without code ZG2 (Permanent all-wheel drive)

Remove/install rear engine cross member

AR22.10-S-1170S

6.2

Remove rear engine support with engine mount

Model 639 with code ZG2 (Permanent all-wheel drive)

Remove/install rear engine support with engine mount

AR22.10-S-4410S

7

Remove speedometer sensor

Model 639.6/70 with transmission 716.6
with code BW1 (Omission of Telligent stability control)

AR54.75-S-5360S

 Only perform the operation steps for removing the speedometer sensor from the transmission.

8

Remove speed inductive sensor (B6/4)

Model 639 with transmission 716.6
with code J19 (Tachograph 1 day/2 drivers automatic (CM))
Model 639 with transmission 716.6
with code JD1 (Digital tachograph)

 Installation: Ensure that electrical wiring harness is routed correctly.

 Bolt, speed sensor for tachograph to transmission

*BA26.19-N-1001-01I

9

Unclip shift cables (5) from gearshift linkage

 To do so, detach the ball sockets (6) from the ball heads and pull sideways out of the guide.

 Installation: Lightly grease the ball sockets (6) and ball heads. Check that the shifting mechanism is functioning correctly.

Long-life grease

*BR00.45-Z-1001-06A

Adjust shift cables (5) if necessary; see:



Adjust shift cables for manual transmission.

AR26.60-S-6633SD

10

Detach shift cables (5) from transmission

 To do so, detach the shift cables (5) from the bracket (7), place to one side and tie up.

 Installation: Check the locking plates (8); replace if necessary.

11

Remove propeller shaft (9)

Model 639 with code ZG2 (Permanent all-wheel drive)

 To do so, remove the bolts and tie the propeller shaft (9) to the underfloor.

 Installation: Replace screw/bolts.

 Fit bolt, propeller shaft to transmission

*BA41.10-N-1001-01L

 Fit bolt, propeller shaft to transfer case

*BA41.10-N-1007-01L

12

Remove bracket (10)

 To do so, unscrew the nuts (11) and remove the bolts (12).

 Screw/bolt, manual transmission to engine

*BA26.10-N-1001-01F

 Model 636, 639 with engine 646Nut/bolt, bracket to front exhaust system

*BA49.10-N-1003-01I

13

Detach ground line (13)

 To do so, remove the bolt (14) and place the ground line (13) to one side.

 Screw/bolt, manual transmission to engine

*BA26.10-N-1001-01F

14

Remove starter from transmission

 To do this, remove the bolts (15). Do not detach the electrical lines from the starter.

 Screw/bolt, manual transmission to engine

*BA26.10-N-1001-01F

15

Support and secure transmission



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Commercially available tools
Major assembly lifter.

16

Remove remaining bolts, transmission to engine

 Screw/bolt, manual transmission to engine

*BA26.10-N-1001-01F

17

Remove transmission by moving toward rear and lower

 Installation: Lightly grease the transmission input shaft.

Long-life grease

*BR00.45-Z-1001-06A

18

Detach transfer case from transmission

Model 639 with code ZG2 (Permanent all-wheel drive)
Only if further work is to be performed on the transmission.

 Bolt, transfer case to intermediate flange/transmission

*BA28.10-N-1002-01G



Check

19

Perform visual inspection of central clutch release bearing, grooved ball bearing and flywheel



Notes on working on central clutch release bearing of transmission

AH26.40-N-1001-01S

 Replace any damaged parts.

20

Install in the reverse order

21

Bleed clutch operating system

AR25.20-S-0070S



Check

22

Perform a function check on clutch

23

Check oil level and correct if necessary

 To do this, remove oil filler screw. If necessary, correct the oil level by topping up oil to the bottom edge of the oil filler opening.

 Filling screw

*BA26.40-N-1002-01J

 Danger !

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

24

Check for leaktightness with engine running

 Visual inspection only.

 Manual transmission, complete

Number

Designation

Model 636 with transmission 711.680, 716.652
Model 639 with transmission 711.680, 716.637/652

BA26.10-N-1001-01F

Screw/bolt, manual transmission to engine

Nm

38

 Sensors

Number

Designation

Transmission 711.680/683, 716.637/652

BA26.19-N-1001-01I

Bolt, speed sensor for tachograph to transmission

Nm

10

 Transmission housing

Number

Designation

Model 636 with transmission 711.680, 716.652

Model 639 with transmission 716.637/652

BA26.40-N-1002-01J

Filling screw

Nm

35

35

 Complete transfer case

Number

Designation

Model 639
with code ZG2 (Permanent all-wheel drive)
except code XZ1 (Model generation 1)

Model 639
with code XZ1 (Model generation 1)
with code ZG2 (Permanent all-wheel drive)

BA28.10-N-1002-01G

Bolt, transfer case to intermediate flange/transmission

M8

Nm

25

19

 Propeller shaft

Number

Designation

MODEL 639.### ## up to 195159 with TRANSMISSION 716.6 with CODE ZG2

MODEL 639.### ## as of 195160 with TRANSMISSION 716.6 with CODE ZG2

BA41.10-N-1001-01L

Fit bolt, propeller shaft to transmission

Stage 1

Nm

–

–

Stage 2

°

–

–

 Propeller shaft

Number

Designation

MODEL 639.### ## up to 195159 with TRANSMISSION 716.6 with CODE ZG2

MODEL 639.### ## as of 195160 with TRANSMISSION 716.6 with CODE ZG2

BA41.10-N-1007-01L

Fit bolt, propeller shaft to transfer case

Stage 1

Nm

15

15

Stage 2

°

90

90

 Exhaust system

Number

Designation

Engine 646 in model 636, 639

BA49.10-N-1003-01I

Nut/bolt, bracket to front exhaust system

Nm

23

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11