Remove/install transmission

AR26.10-T-0020AA

Remove/install transmission

15.2.12

 

Remove/install

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect ground lead from battery

AR54.18-T-0002AA



Notes on battery

All models

AH54.10-P-0001-01A

2

Release compressed air from compressed air system

 Actuate drain valve on reservoirs.

3

Remove passenger seat above transmission maintenance flap.

Except model 671 FACELIFT 2000

Model 671 FACELIFT 2000

AR91.21-T-4460D

4

Remove transmission service flap

5.1

Detach shift rod from transmission

Only on transmission 714.120/140 with "Manual" gearshift, code G62

5.2

Detach shift cables (1) from bracket (2) and from reversing levers (3, 4)

Only on transmission 714.120/140 with "Control cable" gearshift, code G63

 Do not make any changes to the settings of the shift cables (1).

5.3.1

Detach compressed-air lines from shift cylinders on transmission

Only on transmission 714.120/140 with electronic power shift (EPS), code G61

5.3.2

Unplug connectors from sensors for shift cylinders on transmission

Only on transmission 714.120/140 with electronic power shift (EPS), code G61

6

Detach bracket (5) from transmission

7

Raise vehicle

AR00.60-T-1000AA

8

Remove engine compartment encapsulation under the transmission

AR61.20-T-1105AA

9

Drain transmission oil

 Only perform step if the transmission oil is being changed or the transmission is disassembled.



Manual transmission - oil change

AP26.00-T-2601BA

10

Remove propeller shaft

AR41.10-T-0050A

11

Detach bracket (6) on end face of transmission housing

12

Detach bracket (7) on side of transmission housing

13

Disconnect electrical connector from backup lamp switch

14

Disconnect electrical connector from output speed sensor

15

Detach clutch booster (8) from transmission

 Do not disconnect hydraulic lines. Tie clutch booster (8) securely to frame.

AR25.20-T-0300AA

 Installation: When installing the clutch booster (8), insert the plunger into the booster.

16

Remove plunger for operating release fork

 So that the clutch release fork can retract out of the groove in the clutch release bearing when the transmission is detached.

 Installation: Latch clutch release bearing into the circlip of the pressure plate: 

Remove/install release mechanism

 Once the clutch release bearing has latched, audibly and perceptibly latch the plunger for operating the clutch release fork into the clutch release fork.

AR25.10-T-0050-03BA

*BR00.45-Z-1062-06A

17

Detach shift damper piston rod (10) from relay lever (9)

Only on transmission 714.120/140 with "Control cable" gearshift, code G63

18

Detach shift damper bracket (11) from transmission and remove shift damper (12)

Only on transmission 714.120/140 with "Control cable" gearshift, code G63

19

Support engine and secure with suitable equipment jack to prevent it falling down and toppling

Engine support device, engine hoist
gotis://A_01_09.0

20

Support transmission using lifting platform and secure with a suitable lashing strap to prevent it from falling or tipping over

Vehicle lift for major assemblies/scissors-type pallet forklift

gotis://A_01_07.1

Lashing straps as tilt control
gotis://H_00.1_05.2

21

Remove bolts from clutch housing on engine housing

 First unscrew the top bolts, then the bottom ones.

 Installation: Do not tilt the transmission with clutch housing when attaching to the flange of the engine housing.

22

Detach right-hand engine support from clutch housing and remove left-hand engine support

23

Slightly lift transmission and pull backwards

 Raise component lifter under engine according to position of transmission.

The clutch release bearing remains on the clutch.

 Installation: Install the clutch release bearing on the clutch release fork before installing the transmission on the engine:



Remove/install release mechanism

AR25.10-T-0050-03BA

24

Clean and lightly grease transmission input shaft

 Remove any excess grease.

*BR00.45-Z-1062-06A

25

Install in the reverse order

26

Fill with transmission oil

 Only perform step if the transmission oil is being changed or the transmission has been disassembled.



Manual transmission - oil change

AP26.00-T-2601BA

Number

Designation

Order number

BR00.45-Z-1062-06A

Lubricating grease, Olista Longtime, DB supply specification 6804.60

A 001 989 36 51 10